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3.55

9925723 R01 - 2015 RZR 900 Service Manual

Cylinder / Piston Removal

CAUTION

Pistons must be removed from the cylinders with the

connecting rods attached.

DO NOT attempt to service the cylinder or pistons

without disassembling the crankcase. Although you can

remove the cylinder and pistons without disassembly,

you will not be able to reassemble the engine because

of the unique cylinder skirt and crankcase design.

1. Perform “ENGINE DISASSEMBLY / INSPECTION -

TOP END” and the “ENGINE DISASSEMBLY /

INSPECTION - LOWER END” procedures.

2. Rotate the engine so the cylinder is facing up.

3. Remove the Cylinder Holding & Camshaft Timing

Plate (PU-50563) from the cylinder.

4. Carefully lift the cylinder and pistons from the upper

crankcase.

5. 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

and measure

warp by inserting a feeler gauge between the straight

edge and the cylinder surface. If warp exceeds the

service limit, replace the cylinder.

Cylinder Warp Limit:

.002" (0.05 mm)

2. Inspect cylinder for wear, scratches, or damage.

NOTE: DO NOT hone the cylinders or attempt to

repair a damaged cylinder by honing.

ENGINE / COOLING SYSTEM

Polaris 2015 RZR 900 Service Manual

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