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3.9
ENGINE
3
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
Safety and Maintenance 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 if required.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
1. Remove radiator cap and slowly add coolant to top of filler
neck.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap and squeeze coolant lines to force air out
of system.
4. Again remove radiator cap and slowly add coolant to top
of fill neck.
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 temp. Check level in reservoir
tank after engine is cool and add coolant if necessary.
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first 10
hours of engine operation or 2 full tanks of fuel.
1. Use only Polaris Premium 4 All Season synthetic oil, or
API certified “SH” oil.Never substitute or mix oil brands.
Serious engine damage can result.
2. Use fuel with a minimum octane of 87 (R+M)/2 method.
3. Change break-in oil and filter at 20 hours or 500 miles,
whichever comes first.
Cylinder Hone Selection/ Honing Procedure
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.
NOTE: See next page for more information on honing.
Honing To Oversize
CAUTION
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.
CAUTION
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.
CAUTION
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 - .003" (.05 - .07 mm) for finish
honing. Refer to piston-to-cylinder clearance
specifications before honing. Complete the sizing with
fine grit stones to provide the proper cross-hatch finish
and required piston clearance.
EXAMPLE OF CROSS HATCH PATTERN