Polaris Ranger 500 2x4 2007, Service Manual

Page: 70 / 345

3.11
ENGINE
3
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 stone approximately 1/2" (1.3 cm) beyond the
bore at the end of each stroke.
• 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.
• 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
I t 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 2 Cycle Lubricant
.
Crankshaft Straightening
Lubricate the bearings and clamp the crankshaft securely in the
Crankshaft Truing Stand (
PN 2870569 ). Refer to the
illustrations below.
NOTE: The rod pin position in relation to the dial
indicator position tells you what action is required to
straighten the shaft.
1. To correct a situation like the one shown in the illustration
below, strike the shaft at point A with a brass hammer.
2. To correct a situation like the one shown in the illustration
below, squeeze the crankshaft at point A. Use tool from
alignment kit.
EXAMPLE OF CROSS HATCH PATTERN
Crankshaft Truing Stand
(PN 2870569)
HIGH .004 (.1 mm)
SUPPORT CRANKSHAFT
HERE.
HIGH .004 (.1 mm)
HIGH .002 (.05 mm)
HIGH .005 (.13 mm)