Polaris 2014 RZR XP 1000, Service Manual, Page: 118 / 474

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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
Piston Ring to Groove Clearance Inspection
1. Measure piston ring to groove clearance (Item 1) by
placing the ring in the ring land and measuring with a
thickness (feeler) gauge. Replace piston and rings if
ring-to-groove clearance exceeds service limits.
Piston Ring to Groove Clearance:
Top / Second Ring:
0.0007 - 0.0023" (0.020 - 0.060 mm)
Service Limit: 0.0047" (0.12 mm)
Piston Ring Installed Gap
1. Place each piston ring (Item 1) inside the cylinder
(Item 2). Use the piston to push the ring squarely into
cylinder, as shown below.
2. Measure installed gap with a feeler gauge (Item 3) at
both the top and bottom of the cylinder.
NOTE: A difference between top and bottom end
gap measurements is a general indication of
cylinder taper (wear). The cylinder should be
measured for taper and out of round.
3. If the installed gap measurement exceeds the
service limit, replace the rings.
Piston Ring Installed Gap:
Top Ring: 0.010 - 0.014" (0.25 - 0.35 mm)
Service Limit: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Second Ring: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Service Limit: 0.028" (0.70 mm)
Oil Control Rails: 0.008 - 0.028" (0.20 - 0.70 mm)
Service Limit: 0.0354" (0.9 mm)
NOTE: 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 10 mm (Item
1) 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, page
3.53“Cylinder Inspection” procedure.
Piston O.D. (Standard):
3.6597 ± 0.0003" (92.959 ± 0.008 mm)
ENGINE