Cylinder Inspection; Piston Disassembly / Inspection - Polaris RZR XP Turbo Service Manual

6. Remove the piston / connecting rod assemblies from
the cylinder.
NOTE
If the pistons are to be reused, mark the pistons so they
are reassembled in the same cylinder bore and
direction from which they were removed (MAG / PTO).

CYLINDER INSPECTION

1. Lay a straight edge across the top surface of the
cylinder at several different points
warp by inserting a feeler gauge between the straight
edge and the cylinder surface. If warp exceeds the
service limit, replace the cylinder.
MEASUREMENT
Cylinder Warp Limit:
.002" (0.05 mm)
2. Inspect cylinder for wear, scratches, or damage.
CAUTION
DO NOT hone the cylinders or attempt to repair a
damaged cylinder by honing.
9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc.
3. Inspect taper and out of round with a dial bore gauge.
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 (0.6" down
from top, the middle, and 1.5" up from bottom).
Record measurements. If cylinder is tapered or out of
round beyond the service limit, the cylinder must be
replaced.

PISTON DISASSEMBLY / INSPECTION

New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder. The arrow will point
q
and measure
1. Note location of the piston circlip gap
(12:00 position).
ENGINE / COOLING SYSTEM
MEASUREMENT
Standard Bore Size:
3.6614 ± .0003" (93 mm ± 0.008 mm)
Cylinder Taper:
Service Limit: .001" (0.025 mm)
Cylinder Out of Round:
Service Limit: .001" (0.025 mm)
NOTE
towards the exhaust side.
3
q
at the top
3.67