Cylinder Block Inspection - Polaris 1999 Sportsman 400 Service Manual

120
9. Tap the cylinder block (F igure 102) with a
soil-faced mallet to break it loose from the mating
surface of the crankcase.
10. Pull straight up and partially remove the cylin-
der block from the piston and the crankcase.
CAUTION
Place a clean shop cloth around the
connecting IUd before the cylinder
block is completely removed to
prevent
any loose parts from fa lling
into
the
crankcase opening. The shop cloth will
also keep the connecting rod ami pis-
ton /i'01l1 falling
against the crankcase
after the cylinder Mock is removed.
II . Lift the cylinder block from the piston and
crankcase.
12. Remove the cylinder base gasket.
13. If loose, remove the two dowel pins from the
crankcase.
14. Install a piston holding fixture under the piston to
protcctthe piston skirt from damage. This fixture (Fig-
ure 11I3) may be purchased or fabricated from wood.
Inspection
A bore gauge and micrometer are required to ac-
curately measure the cylinder bore . Ifthese tools are
not ava ilable, have the measurements performed by
a Polaris dealer ship or machine shop.
I . Remove all gasket residue from the cylinder
block top and bottom gasket surfaces. Both surfaces
must be free of all residue.
2. Wash the cylinder block in solvent.
Dry
with
compressed air.
3. Check the locating dowels holes for cracks or
other damage.
4. Check the cylinder block bore (Figure 104) for
scoring, rust or other visible damage.
5. Measure the cylinder block bore diameter, taper
and out-of-round with a bore gauge (Figure 105) or
inside micrometer. Measure the cylinder bore at the
following locations:
a. 12.7 mm (0.50 in.) down from the top of the
cy linder block.
b. At the center of the bore.
c. 12.7mm (0.50 in.) up from the bottom of the
cylinder block .
CHAPTE R FOUR