Engine Installation Notes; Cylinder Hone Selection And Honing Procedure - Polaris 2007 SPORTSMAN X2 800 Service Manual

ENGINE

Engine Installation Notes

After the engine is installed in the frame, review this checklist
and perform all steps that apply:
General Items
1. Install previously removed components using new gaskets,
seals, and fasteners where applicable.
2. Perform regular checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the daily pre-
ride inspection checklist (refer to Chapter 2 or the Owner's
Manual).
PVT System
1. Adjust center distance of drive and driven clutch. (Chapter
6)
2. Adjust clutch offset, alignment, and belt deflection.
(Chapter 6)
3. Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing. (Chapter 6)
Transmission
1. Inspect transmission operation and adjust linkage if
necessary. Refer to Chapter 2 and Chapter 8.
Exhaust
1. Replace exhaust gaskets. Seal connections with high temp
silicone sealant.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
NOTE: This cooling system contains vent lines to
help purge trapped air during filling. Bleeding
generally should not be necessary.
1. Remove radiator cap and slowly add coolant to the bottom
of filler neck.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap and gently squeeze coolant hoses to
force any trapped air out of system.
4. Again, remove radiator cap and slowly add coolant to the
bottom of fill neck if needed.
5. Start engine and observe coolant level in the radiator.
Allow air to purge and top off as necessary. Reinstall
radiator cap and bring engine to operating temperature.
After engine is cool, check level in reservoir tank and add
coolant if necessary.
NOTE: Should the reservoir tank become empty, it
will be necessary to refill at the radiator and repeat
the bleeding procedure.
3.18
Engine Break-In Period
The break-in period for a Polaris ATV engine is defined as the
first ten hours of operation, or the time it takes to use two full
tanks of gasoline. No single action on your part is as important
as a proper break-in period. Careful treatment of a new engine
will result in more efficient performance and longer life for the
engine. Perform the following procedures carefully.
CAUTION
Use only Polaris Premium 0-40W All Season
synthetic oil or equivalent.
Never substitute or mix oil brands. Serious engine
damage and voiding of warranty can result.
Do not operate at full throttle or high speeds for
extended periods during the first three hours of use.
Excessive heat can build up and cause damage to
close fitted engine parts.
1. Fill fuel tank with unleaded or leaded fuel which has a
minimum pump octane number of 87= (R+ M)/2.
2. Check oil reservoir level indicated on dipstick. Add oil if
necessary (Refer to Chapter 2, "Engine Oil Level" ).
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions. Do not operate at sustained idle or
sustained high speed.
5. Perform regular checks on fluid levels, controls and all
important bolt torques. Pull only light loads during initial
break in.
6. Pull only light loads during initial break-in.
7. Change break in oil and filter at 20 hours or 200 miles.
Cylinder Hone Selection And 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 for nicasil cylinders.
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.
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.