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ENGINE
Piston/Cylinder Clearance (2 Strokes)
Follow new engine break-in procedures after replac-
ing piston/rings. Pre-mix the first tank of fuel. Bleed
oil pump and warm engine thoroughly. Avoid sus-
tained full throttle for the first two tanks of fuel. Confirm
oil system is working properly. Oil level in reservoir
should drop after first tank of fuel.
Cylinder Inspection/Measurement
I nspect cylinder for wear, scratches, or damage. If no
damage is evident, measure cylinder for taper and out
of round with a telescoping gauge and micrometer or
a dial bore gauge. Measure bore 1/2" down from top
of cylinder in two directions - in line with piston pin and
90° to the pin to determine if bore is out of round. Re-
peat measurements at bottom of cylinderto determine
taper or out of round at the bottom. Record all mea-
surements.
Piston Inspection/Measurement (Generic)
1 . Check piston for scoring or cracks in piston crown or
pin area. Excessive carbon buildup below the ring
lands is an indication of piston, ring or cylinder wear.
2.
Measure piston outside diameter at a point 10 mm
(3/8") up from bottom of skirt at a 90° angle to the
direction
of
the
piston
pin.
Record
the
measurement.
NOTE:The piston must be measured atthis pointto pro-
vide accurate piston-to-cylinder clearance measure-
ment.
3.
Subtract this measurement from the maximum
cylinder measurement recorded previously.
If
clearance exceeds the service limit, determine if
piston or cylinder is worn and recondition or replace
as necessary.
Refer to page 3.3 for piston to
cylinder clearance specifications.
10196
3.34
Polaris Industries Inc.
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