Polaris 2006 HAWKEYE 2x4, Repair Manual

Page: 64 / 217

3.26
ENGINE
CYLINDER INSPECTION
1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
on three different levels (1/2” down from top, in the
middle, and 1/2” up from bottom).
5. Record measurements. If cylinder is tapered or out of
round beyond specification, the cylinder must be
honed, bored or replaced.
CYLINDER HONE SELECTION/ HONING
PROCEDURE
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 DEGLAZE
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:
• 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 stones approximately 1/2”
(1.3 cm) above and below the bore at the end of
each stroke.
• Release the hone at regular intervals and inspect
the bore to determine if it has been sufficiently
deglazed, and to check for correct cross-hatch.
NOTE : Do not allow cylinder to heat up during
honing .
• After honing has been completed, THOROUGHLY
clean the cylinder to remove all honing residue.
IMPORTANT: Clean the Cylinder After Honing
Wash the cylinder in a solvent, then in hot, soapy water.
Use electrical contact cleaner if necessary to clean areas
that cannot be scrubbed. Rinse thoroughly, dry with
compressed air, and oil the bore immediately with Polaris
4 Cycle Lubricant to prevent the formation of surface rust.
Cylinder Warp:
.002” (.05 mm) MAX
Cylinder Taper
Limit: .002” (.05 mm) Max.
Cylinder Out of Round
Limit: .002” (.05 mm) Max.
1/2” Down From Top of Cylinder
1/2” Up From Bottom
X
X
X
Y
Y
Y
CAUTION
A hone which will straighten as well as remove ma-
terial from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is
not advised. Polaris recommends using a rigid
hone or arbor honing machine.