Cylinder Hone Selection And Honing Procedure; Honing To Deglaze; Cleaning The Cylinder After Honing; Piston-To-Cylinder Clearance - Polaris RZR 800 2013 Manual

ENGINE
Cylinder Hone Selection and 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.
CAUTION
A hone which will straighten as well as remove material
from the cylinder is very important. Using a common
spring loaded glaze breaker for honing is not advised
for nicasil cylinders.
Polaris recommends using a rigid hone orarbor honing
machine.

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:
• Honing should be done with a diamond hone.
Cylinder could be damaged if the hone is not hard
enough to scratch the nicasil lining.
• 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 de-
glazed, and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during
honing.
• After honing has been completed, inspect cylinder
for thinning or peeling.
If cylinder wear or damage is excessive, it will be
necessary to replace the cylinder. The cylinders are lined
with a nicasil coating and are not repairable. Hone only
enough to de-glaze the outer layer of the cylinder bore.
3.40
IMPORTANT: Clean the cylinder after honing

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 Lubricant.

Piston-to-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from
the bottom of the piston at a right angle to the direction of
the piston pin.
Subtract this measurement from the maximum cylinder
bore measurement obtained during the "Cylinder
Inspection" procedure.
See "800 EFI Engine Service Specifications", page
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
Piston to Cylinder Clearance:
3.9