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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod RZR800HO-11 (PN 1204276)
Cylinder
Cylinder - Surface warp limit
(mating with cylinder head)
0.004" (0.10 mm)
Cylinder Bore - Standard 3.1495" (80 mm)
Cylinder Taper Limit 0.00031" (0.008 mm)
Cylinder Out of Round Limit 0.00030" (0.0075 mm)
Cylinder to Piston Clearance .0015" .00059" (.040 .015 mm)
Lifter
Lifter Outer Diameter Standard 0.84245" 0.00025" (21.39 8 0.00635 mm)
Lifter Block Bore 0.8438" 0.00062" (21.4322 0.0157 mm)
Piston
Piston - Standard 3.14803" .00028" (79.960 .007 mm)
Piston Standard Inner Diameter of
Piston Pin Bore
0.70902" .00012" (18.009 0.003 mm)
Piston Pin
Piston Pin Outer Diameter 0.70866" - 0.70846" (18 - 17.995 mm)
Piston Pin - Standard Clearance - Piston Pin to
Pin Bore
0.00047" 0.00024" (0.012 0.006 mm)
Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20° C)
Piston / Connecting Rod / Crankshaft - Engine Specifications
Main Components: Piston / Connecting Rod RZR800HO-11 (PN 1204276)
Piston Ring
Installed
Gap
Top Ring - Standard 0.0059 - 0.0138" (0.15 - 0.35 mm)
Top Ring - Limit > 15% Leakdown
Second Ring - Standard 0.0098 - 0.0197" (0.25 - 0.50 mm)
Second Ring - Limit > 15% Leakdown
Oil Ring - Standard 0.0197 0.0098" (0.50 0.25 mm)
Oil Ring - Limit > 15% Leakdown
Ring to
Groove
Clearance
Top Ring - Standard 0.0024" 0.0008" (0.060 0.020 mm)
Top Ring - Limit > 15% Leakdown
Second Ring - Standard 0.0028" 0.0008" (0.070 0.020 mm)
Second Ring - Limit > 15% Leakdown
Connecting Rod
Connecting Rod Small End I.D. 0.7096" 0.70846" (18 17.995 mm)
Connecting Rod Small End
Radial Clearance
0.00098" 0.00039" (0.025 0.010 mm)
Connecting Rod Big End
Side Clearance
0.01181" 0.00591" (0.30 0.15 mm)
Connecting Rod Big End
Radial Clearance
0.0015" 0.0006" (0.038 0.015 mm)
Crankshaft Crankshaft Runout Limit 0.00236" (0.060 mm)