Cylinder Inspection - Polaris 2008 sportsman 800efi Service Manual

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder (B) for warp using a straight
edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.
A
B
A
C
Cylinder Warp: .004" (0.1 mm) Max.
B
Measure at different
points on surface.
= In. / mm.
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). Record measurements. If cylinder is
tapered or out of round beyond .002", the cylinder must be
replaced.
1/2" Down From Top of Cylinder
1/2" Up From Bottom
Cylinder Taper Limit:
.002" (9.05mm) Max.
Cylinder Out of Round:
Limit: .002" (.0 mm) Max.
700/800 Standard Bore Size
(Both Cylinders): 3.1496
ENGINE
= In. / mm.
(80 mm)
"
3.31
3