Cylinder Warpage Measurement; Piston & Piston Ring Removal; Piston & Piston Ring Inspection - Victory Cross Roads Classic Service Manual

CYLINDER & PISTON

Cylinder Warpage Measurement

1. Inspect cylinder for warpage at cylinder head surface
and base gasket surface.
2. Place a straight edge diagonally across cylinder
mating surfaces in several positions. Attempt to slide
a .05mm (.002") feeler gauge under the straight edge
in each position.
3. Replace cylinder if warped beyond the service limit.
Piston & Piston Ring Removal
1. Cover crankcase with a clean shop towel to prevent
piston clip from falling into the crankcase.
2. Remove the left piston pin circlip.
3. Push piston pin out to left side of engine and remove
the piston.
4. Rotate rings in piston groves. Rings should rotate
freely in grooves.
5. Clean carbon deposits from piston.
8.6
9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual
6. Spread rings only wide enough to remove them from
piston. Spreading rings too wide will damage them.
7. Clean piston ring grooves. Break or cut a piston ring in
half. File or grind one edge square and remove all
burrs. Use this piston ring to carefully clean piston ring
grooves.
NOTE: A soft wire brush may be used to clean the top of
the piston. Do not use a wire brush to clean the sides of
the piston or the piston ring groves.
Piston & Piston Ring Inspection
10 mm
1. Visually inspect piston for cracks, excessive wear,
scoring, etc.
2. Measure piston skirt O.D. (90
bottom of piston skirt). Compare to specifications on
page 8.3. Replace piston if worn beyond the service
limit.
3. Calculate Piston to Cylinder Clearance. Subtract
piston O.D. from cylinder bore I.D. and compare to
specification listed on page 8.3.
4. Replace parts that do not meet specification.
NOTE: If piston-to-cylinder clearance exceeds service
limit,
clearance.
service limits with a new piston, cylinder must be
replaced.
© Copyright 2012 Polaris Sales Inc.
Piston O.D. Measurement
Piston to Cylinder Clearance Calculation
Cylinder I.D.
- Piston O.D.
= Piston to Cylinder Clearance
measure a new piston
If piston-to-cylinder
Piston Pin

to pin and 10 mm from
and re-calculate
clearance exceeds