3.56
9940259 R02 - 2022
RZR
PRO R / PRO R 4 Service Manual
© Copyright Polaris Industries Inc.
PISTON DISASSEMBLY / INSPECTION
NOTICE
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
IMPORTANT
Mark the exhaust piston with a paint pen prior to
removal.
1. Note location of the piston circlip gap
q
at the top
(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.
CAUTION
DO NOT apply heat to piston rings or a loss of radial
tension could result.
3. Measure piston pin bore I.D. in two directions (90°
apart). Replace piston and piston pin if out of
specification.
MEASUREMENT
Piston Pin Bore I.D.:
0.8663 - 0.8665” (22.004 - 22.010 mm)
Service Limit:
0.8677 in (22.042 mm)
4. Measure piston pin O.D. in two directions (90° apart)
at three locations on the length. Replace piston and
piston pin if out of specification.
MEASUREMENT
Piston Pin O.D.:
0.8659 - 0.8661” (21.995 - 22.000 mm)
Service Limit:
0.8651 in (21.975 mm)
