Cylinder Honing; Honing Procedure; Cleaning The Cylinder After Honing - Polaris IQ 2007 Service Manual

Cylinder Honing

The cylinder bore must be de-glazed whenever new pis-
ton rings are installed. A light honing with fine stones re-
moves 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 vi-
bration, poor sealing, and overheating of the rings due to
blow-by and reduced contact with the cylinder wall. Ser-
vice life of the pistons and rings will be greatly reduced.
NOTE: A Nicasil cylinder can be lightly honed with a
soft stone hone but an not be oversized.
EXAMPLE OF A CROSS HATCH PATTERN

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
Engine and Cooling Systems
until stone contacts the cylinder walls (DO NOT
OVERTIGHTEN). Cylinders may be wet or dry honed
depending on the hone manufacturer's recommendations.
Wet honing removes more material faster and leaves a more
distinct pattern in the bore. Using a .50" (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 .5"
(1.2 cm) beyond the bore at the end of each stroke.
4. 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 or boring
is complete.
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