Page 220 - Manual_Polaris_RZR_ProXP-20-21

ENGINE / COOLING SYSTEM

3. If the installed gap measurement exceeds the service CONNECTING ROD INSPECTION
limit, replace the rings.
1. Inspect the small end and big end of connecting rod
MEASUREMENT (and matching rod cap) for damage, galling of surface
or pitting.
Piston Ring Installed Gap:
Top Ring: .010 - .016" (0.24 - 0.40 mm) 2. Measure small end I.D. in two directions as shown.
Service Limit: .0196" (0.50 mm) Record measurements and compare to
specifications. Replace connecting rod if worn past
the service limit specification.
Second Ring: .015 - .025" (0.37 - 0.63 mm)
Service Limit: .028" (0.70 mm)

Oil Control Rails: .010 - .040" (0.25 - 1.02 mm)
Service Limit: .045" (1.15 mm)

IMPORTANT
Always check piston ring installed gap when installing
new rings and/or a new cylinder.

PISTON TO CYLINDER CLEARANCE
Measure piston outside diameter at a point 13 mm up
from the bottom of the piston, at a right angle to piston
pin bore. MEASUREMENT
Connecting Rod Small End I.D.:
Subtract measurement from maximum measurement
obtained in Step 4 of “Cylinder Inspection” procedure. .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°

MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)

MEASUREMENT
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 mm)

3.76 9930583 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.