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ENGINE
Piston/Cylinder Clearance (2 Strokes)
Cylinder Inspection/Measurement
CAUTION
Careless handling of the cylinder, pistons or rings may
cause irreparable damage. Handle these parts with
care. Do not damage the gasket surfaces during the
cleaning operation.
Inspect cylinder for wear, scratches, or damage. If no
damage is evident, measure cylinder for taper and out
of round with a telescoping gauge and micrometer or
a dial bore gauge. Measure bore 1/2" down from top
of cylinder in two directions - in line with piston pin and
90° to the pin to determine if bore is out-of-round. Re-
peat measurements at bottom of cylinder to determine
taper or out of round. Record all measurements.
Piston Inspection/Measurement (2 Stroke)
1. Check piston for scoring or cracks in piston crown or
pin area. Excessive carbon buildup below the ring
lands is an indication of piston, ring or cylinder wear.
2. Measure piston outside diameter at a point 10 mm
(3/8") up from bottom of skirt at a 90° angle to the
direction of
the piston pin.
measurement.
NOTE:The piston must be measured at this point to pro-
vide accurate piston-to-cylinder clearance measure-
ment.
3. Subtract this measurement from the maximum
cylinder measurement recorded previously.
clearance exceeds the service limit, determine if
piston or cylinder is worn (calculate clearance with a
new piston) and recondition the cylinder or replace
piston as necessary. Refer to page 3.4 for piston to
cylinder clearance specifications.
4/99
Record the
If
Measure 3/8" (10 mm) up from bottom of skirt
3.36
1/2" Down From Top of Cylinder
Y
X
Y
X
1/2" Up From Bottom
90° to pin
Polaris Sales Inc.
3/8"
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Troubleshooting
