Cylinder Honing; Honing Tools; Honing Procedure; Cleaning The Cylinder After Honing - Polaris 600 RUSH 2010 Manual

Engine/Cooling/Exhaust

Cylinder Honing

The cylinder bore must be de-glazed whenever new
piston rings are installed. A light honing with fine stones
removes only a very small amount of material. A proper
crosshatch pattern is important to provide a surface that
will hold oil, and allow the rings to seat properly. If the
crosshatch is too steep, oil retention will be reduced. A
crosshatch angle which is too shallow will cause ring
vibration, poor sealing, and overheating of the rings due
to blow-by and reduced contact with the cylinder wall.
Service life of the pistons and rings will be greatly
reduced.
NOTE: A Nicasil cylinder can be lightly honed with a
320 grit stone hone but cannot be oversized.
EXAMPLE OF A CROSS HATCH PATTERN

Honing Tools

The following tools are recommended:
• Ammco 3950 Hone Kit - SPX PN 2870303 /
commercially available
• Ammco 3956 Honing Stones (320 grit / Oversize)
• Honing Oil - Commercially Available
3.14

Honing Procedure

1. Wash the cylinder with cleaning solvent.
2. Clamp the cylinder in a soft jawed vise by the cylinder
studs.
3. Place hone in cylinder and tighten stone adjusting
knob until stone contacts the cylinder walls (DO NOT
OVERTIGHTEN).
4. Apply honing oil to the stones and cylinder walls. Wet
honing removes more material faster and leaves a
more distinct pattern in the bore.
5. Using a 1/2" (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/
2" (1.2 cm) beyond the bore at the end of each stroke.
6. Release the hone at regular intervals to inspect bore
size and finish.

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 Premium 2 Cycle Lubricant.
NOTE: Always check piston to cylinder clearance
and piston ring installed gap after honing is complete.