Piston Disassembly / Inspection - Polaris RZR XP 1000 Service Manual

Piston Disassembly / Inspection

NOTE: New pistons are directional (intake vs.
exhaust), but can be placed in either cylinder.
1. Note location of the piston circlip gap
(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.
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
3. Measure piston pin bore I. D. in two directions (90°
at the top
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4. Measure piston pin O.D. in two directions (90° apart)
© Copyright 2014 Polaris Industries Inc.
ENGINE / COOLING SYSTEM
apart). Replace piston and piston pin if out of
specification.
Piston Pin Bore I.D.:
0.7877 - 0.7881" (20.009 - 20.018 mm)
Service Limit:0.7893" (20.05 mm)
at three locations on the length. Replace piston and
piston pin if out of specification.
Piston Pin O.D.:
0.7873 - 0.7875" (20.000 - 20.005 mm)
Service Limit: 0.7866" (19.98 mm)
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