ENGINE
3.11
CYLINDER HONE SELECTION/HONING PROCEDURE
Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a
common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid
hone or arbor honing machine which also has the capability of oversizing.
Cylinders may be wet or dry honed depending upon the hone manufacturer’srecommendations. Wet honing re-
moves more material faster and leaves a more distinct pattern in the bore.
CAUTION:
HONING TO OVERSIZE
If cylinder wear or damage is excessive, it will be nec-
essary 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
boresize,orbyroughhoningfollowedbyfinishhoning.
For oversize honing always wet hone using honing oil
andacoarseroughingstone. Measurethepiston(see
pistonmeasurement)androughhoneto thesizeofthe
piston. Always leave.002-.003″ (.05-.07mm)forf in-
ishhoning. Refertopiston-to-cylinderclearancespec-
ifications onpage3.5before honing.Completethesiz-
ing 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 to hone manufacturer’s instructions, or these
guidelines:
S Useamotorspeedof approximately 300-500RPM, runthe honein andout ofthe cylinder rapidly untilcutting
tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to
bring the stone approximately 1/2″ (1.3 cm) beyond the bore at the end of each stroke.
S Release the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check
piston fit. NOTE: Do not allow cylinder to heat up during honing. The thinner areas of the liner around the
ports will expand causing uneven bore.
S Afterhoninghasbeencompletedinspectallportopeningareasforroughorsharpedges. Applyaslightcham-
fer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and
exhaust ports.
IMPORTANT:
CLEANING THE CYLINDER AFTER HONING
Itisveryimportantthatthecylinderbethoroughlycleanedafterhoningtoremoveallgritmaterial. W ashthecylinder
in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum
casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly,
dry with compressed air , and oil the bore immediately with Polaris 2 Cycle Lubricant.
EXAMPLE OF CROSS HATCH PATTERN
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