Engine Inspections; Cylinder Head Inspection; Cylinder Measurement; Crankshaft Runout Inspection - Polaris IQ 2007 Service Manual

ENGINE INSPECTIONS

Cylinder Head Inspection

Using a flat bar and a feeler gauge, inspect each cylinder
head for warping. Replace head if warping exceeds .003
(.08mm).
= In. / mm.
Cylinder Head Warp Limit
"
.006

Cylinder Measurement

Inspect each cylinder for wear, scratches, or damage. If no
damage is evident, measure the cylinder for taper and out
of round with a telescoping gauge or a dial bore gauge.
"
Measure the bore 1/2 from the top of the cylinder; in line
with the piston pin and 90
bore is out of round. Repeat the measurements at the
middle and bottom of the cylinder. Use the chart below and
record all measurements.
Cylinder Measurement Worksheet
TOP
X
MIDDLE
X
BOTTOM
X
Out-of-Round = Top X - Top Y and Bottom Y - Bottom X
Taper = Top Y - Bottom Y and Top X - Bottom X
(.015mm)
°
to the pin to determine if the
Y
Y
Y
Engine and Cooling Systems
"
Taper Limit = .002
Out-of-Round Limit = .002

Crankshaft Runout Inspection

1. Support the crankshaft in a set of "V" blocks as shown.
2. Use a dial indicator to measure the runout at the following
locations:
• PTO end = First taper after bearing flat.
• MAG end = 1/2" from bearing flat.
3. Runout deflection cannot exceed .0025" (.07mm).
4. If the runout
specification, crankshaft trueing may correct the deflection.
= In. / mm.
"
(.051mm)
"
(.051mm)
deflection exceeds the maximum
5
5.5