Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 67 / 289

GENERAL INFORMATION
3.9
3. Install radiator cap and squeeze coolant lines to
force air out of system.
4. Again remove radiator cap and slowly add coolant
to top of fill neck.
5. Start engine and observe coolant level in the
radiator. Allow air to purge and top off as
necessary. Reinstall radiator cap and bring
engine to operating temp. Check level in
reservoir tank after engine is cool and add coolant
if necessary.
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first
10 hours of engine operation, or 2 full tanks of fuel.
1. Use only Polaris Premium 4 All Season synthetic
oil, or API certified “SH” oil. Never substitute or mix
oil brands. Serious engine damage can result.
2. Use fuel with a minimum octane of 87 (R+M)/2
method.
3. Change break-in oil and filter at 20 hours or 500
miles, whichever comes first.
CYLINDER HONE
SELECTION/HONING
PROCEDURE
CAUTION:
Selecting a hone which will straighten as well as
remove material from the cylinder is very important.
Using a common spring loaded finger type glaze
breaker for honing is never advised. Polaris
recommends using a rigid hone or arbor honing
machine which also has the capability of oversizing.
Cylinders may be wet or dry honed depending upon
the hone manufacturer’s recommendations. Wet
honing removes more material faster and leaves a
more distinct pattern in the bore.
HONING TO OVERSIZE
CAUTION: If cylinder wear or damage is excessive, it
will be necessary to oversize the cylinder using a new
oversize piston and rings. This may be accomplished
by either boring the cylinder and then finish honing to the
final bore size, or by rough honing followed by finish
honing.
CAUTION: For oversize honing always wet hone
using honing oil and a coarse roughing stone.
Measure the piston (see piston measurement) and
rough hone to the size of the piston. Always leave
.002 - .003
″
(.05 - .07 mm) for finish honing. Refer to
piston-to-cylinder clearance specifications on Page
3.4 before honing. Complete the sizing with fine grit
stones to provide the proper cross-hatch finish and
required piston clearance.
EXAMPLE OF CROSS HATCH PATTERN
A finished cylinder should have a cross-hatch pattern
to ensure piston ring seating and to aid in the retention
of the fuel/oil mixture during initial break in. Hone
cylinder according to hone manufacturer’s
instructions, or these guidelines:
S
Use a motor speed of approximately
300-500 RPM, run the hone in and out of
the cylinder rapidly until cutting tension
decreases. Remember to keep the hone
drive shaft centered (or cylinder centered
on arbor) and to bring the stone
approximately 1/2
″
(1.3 cm) beyond the
bore at the end of each stroke.
S
Release the hone at regular intervals and
inspect the bore to determine if it has been
cleared, and to check piston fit. NOTE: Do
not allow cylinder to heat up during honing.
The thinner areas of the liner around the
ports will expand causing uneven bore.
S
After honing has been completed inspect
all port opening areas for rough or sharp
edges. Apply a slight chamfer to all ports
to remove sharp edges or burrs, paying
particular attention to the corners of the
intake and exhaust ports.
CLEANING THE CYLINDER
AFTER HONING
It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot, soapy water. Pay
close attention to areas where the cylinder sleeve
meets the aluminum casting (transfer port area). Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 4 Cycle
Lubricant.