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3.55

9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual

Cylinder Inspection

1. Lay a straight edge

across the top surface of the

cylinder at several different points and measure warp

by inserting a feeler gauge between the straight

edge and the cylinder surface. If warp exceeds the

service limit, replace the cylinder.

Cylinder Warp Limit:

0.002″ (0.05 mm)

2. Inspect cylinder for wear, scratches, or damage.

NOTE: DO NOT hone the cylinders or attempt to

repair a damaged cylinder by honing.

3. Inspect cylinder for taper and out of round with a dial

bore gauge. Measure in two different directions (front

to back and side to side), on three levels (0.59 in.

down from top, the middle, and 1.54 in. up from

bottom). Record measurements. If cylinder is

tapered or out of round beyond 0.001", the cylinder

must be replaced.

Cylinder Taper:

0.001″ (0.025 mm)

Cylinder Out of Round:

0.001″ (0.025 mm)

Standard Bore Size:

3.6614 ± 0.0003" (93 mm ± 0.008 mm)

ENGINE / COOLING SYSTEM

Polaris RZR XP4 1000 User Manual

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