3.20
ENGINE
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: Follow coolant bleeding procedure outlined
earlier in this chapter
Engine Break-In Period
The break-in period for a Polaris RANGER 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.
1. Fill fuel tank with unleaded or leaded fuel which has a
minimum pump octane number of 87= (R+ M)/2.
2. Check oil 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 oil and oil filter after break-in period at 25 hours.
Cylinder Hone Selection And 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.
Honing To Deglaze
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:
• Honing should be done with a diamond hone. Cylinder
could be damaged if the hone is not hard enough to
scratch the nicasil lining.
• Use a motor speed of approximately 300-500 RPM, run
the hone in and out of the cylinder rapidly until cutting
tension decreases. Remember to keep the hone drive
shaft centered (or cylinder centered on arbor) and to
bring the stones approximately 1/2, (1.3 cm) above and
below the bore at the end of each stroke.
• Release the hone at regular intervals and inspect the
bore to determine if it has been sufficiently de-glazed,
and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during
honing.
• After honing has been completed, inspect cylinder for
thinning or peeling.
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
w a r r a n t y c a n r e s u l t .
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.
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.
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