Cylinder Inspection - Polaris SPORTSMAN 400 2003 Service Manual

scratch the ring lands.
A
4. Repeat procedure for second ring.
The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. The top rail has a locating tab on the end
which fits into a notch (A) in the upper oil ring land of
the piston.
5. Remove the top rail first followed by the bottom
rail.
6. Remove the expander.

CYLINDER INSPECTION

1. Remove all gasket material from the cylinder
sealing surfaces.
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
Cylinder Warpage:
.002² (.05 mm)
3. Inspect cylinder for wear, scratches, or damage.
1/2² Down From Top of Cylinder
X
X
X
1/2² Up From Bottom
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 (1/2² down from top,
in the middle, and 1/2² up from bottom).
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
re-bored oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
3.6221-3.6228I (92.00-92.012mm)
ENGINE
Y
Y
Y
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