Polaris RZR XP 1000 Service Manual

3
3.7
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
ITEM
STANDARD SERVICE LIMIT
Piston
Standard O.D. - Measured 90° to pin, 0.39
in. (10 mm) up from piston skirt
3.6597 ± 0.0003" (92.959 ± 0.008 mm)
-
Piston Pin Bore I.D. (Standard) 0.7877 - 0.7881" (20.009 - 20.018 mm) 0.7893" (20.05 mm)
Piston Pin O.D.
0.7873 - 0.7875" (20.000 - 20.005 mm) 0.7866" (19.98 mm)
Piston Ring
Installed
Gap
Top Ring 0.010 - 0.014" (0.25 - 0.35 mm) 0.0196" (0.5 mm)
Second Ring 0.015 - 0.025" (0.37 - 0.63 mm) 0.028" (0.70 mm)
Oil Control Rails
0.008 - 0.028" (0.20 - 0.70 mm) 0.0354" (0.9 mm)
Ring to
Groove
Clearance
Top Ring
0.0007 - 0.0023" (0.020 - 0.060 mm) 0.0047" (0.12 mm)
Second Ring
Connecting
Rod
Connecting Rod Small End I.D. 0.7879 - 0.7885" (20.015 - 20.030 mm) 0.7897" (20.06 mm)
1 - Marking Conn. Rod Big End Bore I.D. 1.7318 - 1.7321" (43.989 - 43.996 mm)
-
2 - Marking Conn. Rod Big End Bore I.D. 1.7321 - 1.7323" (43.996 - 44.003 mm)
-
3 - Marking Conn. Rod Big End Bore I.D. 1.7323 - 1.7326" (44.003 - 44.010 mm)
-
Crankshaft
B - Marking
Main Journal O.D.
1.6140 - 1.6143" (40.996 - 41.004 mm) 1.6129" (40.970 mm)
G -
Marking
Main Journal O.D.
1.6137 - 1.6140" (40.988 - 40.995 mm) 1.6129" (40.970 mm)
Y - Marking
Main Journal O.D.
1.6134 - 1.6137" (40.980 - 40.987 mm) 1.6129" (40.970 mm)
B - Marking
Rod Journal O.D.
1.6118 - 1.6122" (40.942 - 40.950 mm) 1.6104" (40.906 mm)
G -
Marking
Rod Journal O.D.
1.6115 - 1.6118" (40.934 - 40.941 mm) 1.6104" (40.906 mm)
Y - Marking
Rod Journal O.D.
1.6112 - 1.6115" (40.926 - 40.933 mm) 1.6104" (40.906 mm)
Crankshaft Runout Limit (PTO and MAG)
-
Less than 0.001″
(0.025 mm)
Balance
Shaft
Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm)
ENGINE / COOLING SYSTEM

Polaris RZR XP 1000 Specifications

General

Brand	Polaris
Model	RZR XP 1000
Category	Offroad Vehicle
Language	English