2005 Polaris Sportsman 400/500 Service Manual, Page 68Get this manual
HONING TO OVERSIZE
CAUTION: If cylinder wear or damage is excessive, it will be necessary to oversize the cylinder using new oversize piston and ringsThis may be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by finish honingCAUTION: For oversize honing always wet hone using honing oil and coarse roughing stoneMeasure the piston (see piston measurement) and rough hone to the size of the pistonAlways leave .002.003 (.05.07 mm) for finish honingRefer to piston-to-cylinder clearance specifications on Page 3.4 before honingComplete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearanceto remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust ports