Cylinder Honing 4.43 - Polaris Virage TX 2000 Service Manual

ENGINE
Cylinder Honing
Cylinder Honing
The cylinder bore must be de-glazed whenever new piston rings are installed. A light honing with fine stones
removes only a very small amount of material. A proper Crosshatch pattern is important to provide a surface that
will hold oil, and allow rings to seat properly. If the Crosshatch is too steep, oil retention will be reduced. A cross-
hatch angle which is too shallow will cause ring vibration, poor sealing, and overheating of the rings due to blow-by
and reduced contact with the cylinder wall. Service life of the pistons and rings will be greatly reduced.
Cylinder Hone Selection
Selecting a hone which will straighten as well as remove material from the cylinder is very important. Honing a
cylinder with a spring loaded glaze breaker is never advised. Polaris recommends using a rigid type hone which
also has the capability of oversizing. These hones are manufactured by such companies as Sunnen Products
Company of St. Louis, Missouri; and Ammco Tools, Inc., of North Chicago, Illinois.
De-glazing
If cylinder wear or damage is minimal, hone the cylin
der lightly with finish stones.
1200 Engine Cylinder Honing
On Polaris 1200 engines, it is important to bolt exhaust
manifold to cylinder to be honed and torqued to specifi
cation before honing.
Honing To Oversize
If cylinder wear or damage is excessive, it will be nec
essary to oversize the cylinder using a new oversize
piston and rings. This may be accomplished by either
boring the cylinder and then finish honing to the final
bore size, or by rough honing followed by finish honing.
For oversize honing always wet hone using honing oil
and a coarse roughing stone. Measure the piston (see
piston measurement) and rough hone to the size of the
piston or slightly larger. Always leave .002 - .003" (.05
- .07 mm) for finish honing. Complete the sizing with
fine grit stones to provide the proper cross-hatch finish
and required piston clearance.
Honing Procedure
1 . Wash cylinder with solvent. Clamp cylinder in a
soft jawed vise with exhaust manifold installed and
torqued.
Polaris Sales Inc.
4.43
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