Cylinder Inspection; Cylinder Honing Procedure; Honing To Deglaze - Polaris PREDATOR 50 2009 Manual

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing
surfaces. Refer to specifications at beginning of chapter.
2. Inspect the top of the cylinder for warpage using a straight
edge and feeler gauge.
Cylinder Warp:
.002" (.05 mm) MAX
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2" down from top, in the middle, and 1/
2" up from bottom).
1/2" Down From Top of Cylinder
X
X
X
1/2" Up From Bottom
5. Record measurements. If cylinder is tapered or out of round
beyond specification, cylinder must be bored or replaced.
Cylinder Taper
Limit: .002" (.05 mm) Max.
Cylinder Out of Round
Limit: .002" (.05 mm) Max.
Y
Y
Y
ENGINE / TRANSMISSION

Cylinder Honing Procedure

CAUTION
A hone which will straighten as well as remove
material from the cylinder is very important.
Using a common spring loaded glaze breaker for
honing is not advised. Polaris recommends
using a rigid hone or arbor honing machine.
Cylinders may be wet or dry honed depending upon the hone
manufacturer's recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore.

Honing To Deglaze

A finished cylinder should have a cross-hatch pattern to ensure
piston ring seating and to aid in the retention of the fuel/oil
mixture during initial break in. Hone cylinder according to hone
manufacturer's instructions, or these guidelines:
• Use a motor speed of approximately 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 (or cylinder centered on arbor) and to
bring the stones approximately 1/2" (1.3 cm) above and
below the bore at the end of each stroke.
• Release the hone at regular intervals and inspect the
bore to determine if it has been sufficiently deglazed,
and to check for correct cross-hatch. NOTE: Do not
allow cylinder to heat up during honing.
IMPORTANT: Clean the Cylinder After Honing
Clean cylinder thoroughly after honing to remove all grit
material. Wash cylinder in solvent, then in hot, soapy water.
Rinse thoroughly and dry with compressed air. Oil bore
immediately with engine oil to prevent rust.
If cylinder wear or damage is excessive, replace cylinder. Hone
only enough to deglaze the cylinder bore.
EXAMPLE OF CROSS HATCH PATTERN
3
3.23