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9925723 R01 - 2015 RZR 900 Service Manual
© Copyright 2014 Polaris Industries Inc.
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.
Piston O.D. (Standard):
3.6592 ± .0003" (92.950 ± .008 mm)
Piston to Cylinder Clearance:
.0014 - .0026" (.035 - .065 mm)
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 and compare to
specifications. Replace connecting rod if worn past
the service limit specification.
Connecting Rod Small End I.D.:
0.7879" - 0.7884" (20.015 - 20.025 mm)
Service Limit: 0.7897" (20.06 mm)
3. Install matching rod cap on connecting rod (without
bearings) and install the bolts.
4. Tighten bolts by hand, then torque to Step 1: 9 ft-lb
(12 Nm)
Step 2: 22 ft-lb (30 Nm)
Step 3: Tighten add’n 90° prior to taking any
measurements.
ENGINE / COOLING SYSTEM
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