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9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service

Manual

3.117

PISTON DISASSEMBLY / INSPECTION (1000)

NOTE

New pistons are directional (intake vs. exhaust), but

can be placed in either cylinder.

1. Note location of the piston circlip gap

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.:

.7877 - .7881" (20.009 - 20.018 mm)

Service Limit:

.7893" (20.05 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.:

.7873 - .7875" (20.000 - 20.005 mm)

Service Limit:

.7866" (19.98 mm)

ENGINE / COOLING SYSTEM

Polaris RZR 900 2016 Service Manual

Questions and Answers: