Port Chamfering; Cleaning The Cylinder After Honing; Crankcase Inspection / Bearing Fit; Crankshaft Main Bearing Inspection - Polaris 2003 Pro X Service Manual

ENGINE
Honing Procedure
1. Wash cylinder with solvent. Clamp cylinder securely in a soft jawed vise by the exhaust port studs.
2. Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls (DO NOT
OVERTIGHTEN). Cylinders may be wet or dry honed depending on the hone manufacturer's
recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
Using a 1/2I (13 mm) drill motor rotating at a speed of 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 to prevent edge
loading and always bring the stone approximately 1/2I (1.3 cm.) beyond the bore at the end of each stroke.
Release the hone at regular intervals to inspect bore size and finish. Do not "drag" the hone out of the bore.
Honing Procedure - Nicasil
Ni-Ca-Sil cylinders can be lightly honed if the proper stone is used. Ammco #3955 honing stones (for use with
the Ammco 3950 cylinder hone) are suitable and can be ordered through most automotive supply stores or VST.
See General Information chapter for tool ordering information.

Port Chamfering

Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed. Make sure
there are no sharp edges.
IMPORTANT:

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylin-
der in a solvent, then in hot soapy water. Pay close attention to areas where the cylinder sleeve meets the alumi-
num casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thor-
oughly, dry with compressed air, and oil the bore immediately with Polaris Premium 2 Cycle Lubricant.

Crankcase Inspection / Bearing Fit

Any time crankshaft bearing failure occurs and the case is to be reused, Polaris recommends checking the bear-
ing fit into the case halves using the following procedure.
1. With case halves cleaned, press a replacement
bearing into each of the main bearing journals to
determine a basic amount of press fit. NOTE: Do a
comparison check of all journals by manually
forcing the bearing into the bearing seats noting if
any are noticeably loose or tight. Normal hand
installation will be
recommended interference fit. If the bearing falls
out of the case when the case is inverted, the case
should be replaced.
Crankcase Bearing Interference Fit:
C-3 - .0006 (.015mm) - Crush
C-4 - .001 (.025mm) - Crush

Crankshaft Main Bearing Inspection

1. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 engine oil.
Carefully check each main bearing on the shaft.
NOTE: Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs
of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and
quietly. The inner race of each bearing should fit tightly on the crankshaft. The outer race should be firm with
minimal side to side movement and no detectable up and down movement. Replace any loose or rough bearings.
2.48
an indication of the