3.39
ENGINE / COOLING
3
9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2012 Polaris Sales Inc.
4. Measure piston ring to groove clearance by placing
the ring in the ring land and measuring with a
thickness gauge. Replace piston and rings if ring-to-
groove clearance exceeds service limits.
Piston Ring Installed Gap
1. Place each piston ring (A) inside cylinder (B) using a
piston to push ring squarely into place as shown.
NOTE: Ring should be installed with the mark facing
up
ward.
2. Measure installed gap with a feeler gauge (C) at both
th
e top and bottom of the cylinder.
IMPORTANT: A difference in end gap indicates
c
ylinder taper. The cylinder should be measured for
excessive taper and out of round.
3. If the bottom installed gap measurement exceeds the
se
rvice limit, replace the rings. If ring gap is smaller
than the specified limit, file ring ends until gap is within
specified range.
NOTE: Always check piston ring installed gap after
r
e-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with oil immediately
to remove residue and prevent rust.
Starter Drive Bendix Removal / Inspection
1. Remove stator housing bolts and remove housing.
2. Remove the flywheel nut and washer. Install Flywheel
Pu
ller (PN 2871043) and remove flywheel.
NOTE: Do not thread the puller bolts into the
f
lywheel more than 1/4" or stator coils may be
damaged.
3. Remove starter bendix assembly (
A). Note the thrust
washers located on both sides of the bendix.
4. Inspect the thrust washer for wear or damage and
replace if
necessary.
5. After the bendix is removed, remove the two bolts
r
etaining the starter. Tap on the starter assembly (B)
with a soft faced mallet to loosen the starter from the
crankcase.
See “800 EFI Engine Service Specifications”
on page 3.8
Piston Ring Installed Gap:
See “800 EFI Engine Ser
vice Specifications”
on page 3.8
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