Cylinder Inspection - Polaris RZR XP 1000 2014 Service Manual

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Always replace plain bearings when the crankcase or

connecting rods have been disassembled. Refer to

Bearing Selection Identification Letters and Numbers,

CYLINDER INSPECTION

1. Lay a straight edge

across the top surface of the

cylinder at several different points and measure warp

by inserting a feeler gauge between the straight

edge and the cylinder surface. If warp exceeds the

service limit, replace the cylinder.

Cylinder Warp Limit:

.002" (0.05 mm)

2. Inspect cylinder for wear, scratches, or damage.

DO NOT hone the cylinders or attempt to repair a

damaged cylinder by honing.

9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual

ENGINE / COOLING SYSTEM

3. Inspect cylinder for taper and out of round with a dial

bore gauge. Measure in two different directions (front

to back and side to side), on three levels (0.59" down

from top, the middle, and 1.54" up from bottom).

Record measurements. If cylinder is tapered or out

of round beyond 0.001", the cylinder must be

Cylinder Taper:

.001" (0.025 mm)

Cylinder Out of Round:

.001" (0.025 mm)

Standard Bore Size:

3.6614 ± .0003" (93 mm ± 0.008 mm)

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