3.70
9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc.
MEASUREMENT
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 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.
MEASUREMENT
Connecting Rod Small End I.D.:
.8667 - .8673" (22.015 - 22.03 mm)
Service Limit: .8677" (22.04 mm)
3. Install matching rod cap on connecting rod (without
bearings) and install the bolts.
4. Tighten bolts by hand, then torque to specification
prior to taking any measurements.
TORQUE
Connecting Rod Cap Bolts:
Step 1: 9 ft-lbs (12 Nm)
Step 2: 22 ft-lb (30 Nm)
Step 3: Tighten add’n 90°
5. Using a dial bore gauge, measure big end I.D. in two
directions shown. Remove bearings when taking
measurements
q
. Record measurements and
compare to specifications.
6. Refer to the number printed onto the side of the
connecting rod, closest to the small bore end. This
number represents the bore diameter.
7. The table below lists the big end bore diameter
specifications.
Connecting Rod Big End Bore Diameters
1 2 3
1.8892 -
1.8895"
(47.987 -
47.994 mm)
1.8896 -
1.8898"
(47.995 -
48.001 mm)
1.8898 -
1.8901"
(48.002 -
48.008 mm)
8. Whether using new connecting rods or re-installing
the original ones, refer to the bearing selection chart
provided in the “Connecting Rod Bearing Selection”
procedure in this chapter.
ENGINE / COOLING SYSTEM
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