Polaris RZR 800 2013 User Manual

3.10
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod RZR800-13 (1204620)
Cylinder
Cylinder - Surface warp limit
(mating with cylinder head)
0.004" (0.10 mm)
Cylinder Bore - Standard 3.1495" (80 mm)
Cylinder Taper Limit 0.00031" (0.008 mm)
Cylinder Out of Round Limit 0.00030" (0.0075 mm)
Cylinder to Piston Clearance 0.0015" ± 0.00059" (0.04 ± 0.015 mm)
Lifter
Lifter Outer Diameter Standard
0.84245" ± 0.00025" (21.398 ± 0.00635 mm)
Lifter Block Bore
0.8438" ± 0.00062" (21.4322 ± 0.0157 mm)
Piston
Piston - Standard
3.14803" ± 0.00028" (79.96 ± 0.007 mm)
Piston Standard Inner Diameter of Piston Pin Bore
0.70902" ± 0.00012" (18.009 ± 0.003 mm)
Piston Pin
Piston Pin Outer Diameter
0.70866" - 0.70846" (18 - 17.995 mm)
Piston Pin - Standard Clearance - Piston Pin to Pin
Bore
0.00047" ± 0.00024" (0.012 ± 0.006 mm)
Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20° C)
Piston / Connecting Rod / Crankshaft - Engine Specifications
Main Components: Piston / Connecting Rod RZR800-13 (1204620)
Piston Ring
Installed
Gap
Top Ring - Standard 0.0059 - 0.0138" (0.15 - 0.35 mm)
Top Ring - Limit
> 15% Leakdown
Second Ring - Standard 0.0098 - 0.0197" (0.25 - 0.50 mm)
Second Ring - Limit
> 15% Leakdown
Oil Ring - Standard 0.0197 ± 0.0098" (0.50 ± 0.25 mm)
Oil Ring - Limit
> 15% Leakdown
Ring to
Groove
Clearance
Top Ring - Standard 0.0024" ± 0.0008" (0.060 ± 0.02 mm)
Top Ring - Limit
> 15% Leakdown
Second Ring - Standard 0.0028" ± 0.0008" (0.070 ± 0.02 mm)
Second Ring - Limit
> 15% Leakdown
Connecting Rod
Connecting Rod Small End I.D. 0.7096"- 0.70846" (18 - 17.995 mm)
Connecting Rod Small End
Radial Clearance
0.00098" ± 0.00039" (0.025 ± 0.01 mm)
Connecting Rod Big End
Side Clearance
0.01181" ± 0.00591" (0.30 ± 0.15 mm)
Connecting Rod Big End
Radial Clearance
0.0015" ± 0.0006" (0.038 ± 0.015 mm)
Crankshaft Crankshaft Runout Limit
0.00236" (0.06 mm)
ENGINE

Polaris RZR 800 2013 Specifications

General

Brand	Polaris
Model	RZR 800 2013
Category	Offroad Vehicle
Language	English