Piston To Cylinder Clearance; Connecting Rod Inspection - Polaris RZR XP Service Manual

3. If the installed gap measurement exceeds the service
limit, replace the rings.
MEASUREMENT
Piston Ring Installed Gap:
Top Ring: .010 - .016" (0.24 - 0.40 mm)
Service Limit: .0196" (0.50 mm)
Second Ring: .015 - .025" (0.37 - 0.63 mm)
Service Limit: .028" (0.70 mm)
Oil Control Rails: .010 - .040" (0.25 - 1.02 mm)
Service Limit: .045" (1.15 mm)
IMPORTANT
Always check piston ring installed gap when installing
new rings and/or a new cylinder.

PISTON TO CYLINDER CLEARANCE

Measure piston outside diameter at a point 13 mm up
from the bottom of the piston, at a right angle to piston
pin bore.
Subtract measurement from maximum measurement
obtained in Step 4 of "Cylinder Inspection" procedure.
MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)
MEASUREMENT
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 mm)
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM

CONNECTING ROD INSPECTION

1. Inspect the small end and big end of connecting rod
(and matching rod cap) for damage, galling of surface
or pitting.
2. Measure small end I. D. in two directions as shown.
Record measurements
specifications. Replace connecting rod if worn past
the service limit specification.
MEASUREMENT
Connecting Rod Small End I.D.:
.8667 - .8673" (22.015 - 22.03 mm)
Service Limit: .8677" (22.04 mm)
3. Install matching rod cap on connecting rod (without
bearings) and install the bolts.
4. Tighten bolts by hand, then torque to specification
prior to taking any measurements.
TORQUE
Connecting Rod Cap Bolts:
Step 1: 9 ft-lbs (12 Nm)
Step 2: 22 ft-lb (30 Nm)
Step 3: Tighten add'n 90°
and compare to
3
3.81