Piston Disassembly / Inspection - Polaris RZR 900 2015 Service Manual

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3. Inspect taper and out of round with a dial bore

4. 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 in.

down from top, the middle, and 1.54 in. up from

bottom). Record measurements. If cylinder is

tapered or out of round beyond the service limit, the

cylinder must be replaced.

Cylinder Taper:

Service Limit: 0.001" (.025 mm)

Cylinder Out of Round:

Service Limit: 0.001" (.025 mm)

Standard Bore Size:

3.6614 ± .0003" (93 mm ± .008 mm)

9926814 R08 -

PISTON DISASSEMBLY / INSPECTION

New pistons are directional (intake vs. exhaust), but

1. Note location of the piston circlip gap

(12:00 position) or bottom (6:00 position).

2. Remove piston circlip and push piston pin out of

piston. If necessary, heat the crown of the piston

slightly with a heat gun if pin cannot be removed by

hand. Discard circlips.

DO NOT apply heat to piston rings or a loss of radial

2015-2016 RZR 900

ENGINE / COOLING SYSTEM

can be placed in either cylinder.

tension could result.

2016 RZR S 1000 Service

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