Honing To Oversize; Engine Lubrication; Oil Pressure Test - Polaris Trail Boss 330 2003 Service Manual

If cylinder wear or damage is excessive, it will be
necessary to replace the cylinder. Hone only enough
to deglaze the outer layer of the cylinder bore.
EXAMPLE OF CROSS HATCH PATTERN

HONING TO OVERSIZE

If cylinder wear or damage is excessive, it will be
necessary 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. Always leave .002 - .003² (.05 - .07 mm) for
finish honing. Refer to piston-to-cylinder clearance
specifications on Page 3.2 before honing. Complete the
sizing with fine grit stones to provide the proper
cross-hatch finish and required piston clearance.
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
instructions, or these guidelines:
G
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 stone approximately 1/2²
(1.3 cm) beyond the bore at the end
of each stroke.
G
Release the hone at regular intervals
and inspect the bore to determine if
it has been cleared, and to check
piston fit. NOTE:
cylinder to heat up during honing.
The thinner areas of the liner around
the ports will expand causing an
uneven bore.
G
After honing has been completed
inspect all port opening areas for
to hone manufacturer's
Do not allow
rough or sharp edges. Apply a slight
chamfer to all ports to remove sharp
edges or burrs, paying particular
attention to the corners of the intake
and exhaust ports.
IMPORTANT: Clean the Cylinder After Honing
It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 4 Cycle
Lubricant to prevent the formation of surface rust.

ENGINE LUBRICATION -

ES32PF10
Oil Type . . . . . Polaris Premium 0--40W Synthetic
(PN 2871281)
Capacity . . . . . Approximately 2 U.S. Quarts (1.9 l)
Filter . . . . . . . . . . . . . . .
OIl Filter Wrench . . .
Drain Plug/
Screen Fitting . . . . . .
Oil Pressure
Specification
(ES32PF10) . . . . . . . . .

OIL PRESSURE TEST

ES32PF10
WARNING: Oil temperature and pressure can cause
serious injury and damage. Wear the proper safety
gear when performing these procedures.
1. Remove lower blind plug behind oil filter on
crankcase.
2. Insert a 1/8" NPT oil pressure gauge adaptor into
the crankcase and attach gauge.
ENGINE
PN 3084963
PV- -43527
14 ft. lbs. (19 Nm)
71-99 PSI @ 3000 RPM,
Polaris 0W--40 Synthetic
(Oil temp at 122_F 50_C)
3.7