Cylinder Inspection; Cylinder Hone Selection / Honing Procedure - Polaris A12MH46AX Service Manual

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.
Cylinder Warpage:
.002" (.05 mm)
3. Inspect cylinder for wear, scratches, or damage.
1/2" Down From Top of Cylinder
X
X
X
1/2" Up From Bottom
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).
3.32
Y
Y
Y
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
5. Record measurements. If cylinder is tapered, or out
of round beyond .002, the cylinder must be re-bored
oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
(EH500PLE 498cc )
3.6221 - 3.6228" (92.00 - 92.012 mm)
(EH46PLE 455cc Carbureted)
3.4606-3.4614" (87.90-87.92 mm)

Cylinder Hone Selection / Honing Procedure

Selecting a hone which will straighten as well as
remove material from the cylinder is very
important. Using a common spring loaded finger
type glaze breaker for honing is never advised.
Polaris recommends using a rigid hone or arbor
honing machine which also has the
capability of oversizing.
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.
NOTE: See next page for more information on
honing.
CAUTION