2009 Polaris Scrambler 500 4x4 2x4 factory service manual, Page 59Get this manual

2009 Polaris Scrambler 500 4x4 2x4 factory service manual, Page 59

ENGINE 3Install radiator cap and squeeze coolant lines to force air out of system4Again remove radiator cap and slowly add coolant to top of fill neck5Start engine and observe coolant level in the radiatorAllow air to purge and top off as necessaryReinstall radiator cap and bring engine to operating tempCheck level in reservoir tank after engine is cool and add coolant if necessaryEngine Break In Period Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or full tanks of fuel1Use only Polaris Premium All Season synthetic oil, or API certified "SH" oilNever substitute or mix oil brandsSerious engine damage can result2Use fuel with minimum octane of 87 (R+M)2 method3Change break-in oil and filter at 20 hours or 500 miles, whichever comes firstEXAMPLE OF CROSS HATCH PATTERN finished cylinder should have cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fueloil mixture during initial break inHone cylinder according to hone manufacturer's instructions, or these guidelines: Use motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreasesRemember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stone approximately 12 (1.3 cm) beyond the bore at the end of each strokeRelease the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check piston fitNOTE: Do not allow cylinder to heat up during honingThe thinner areas of the liner around the ports will expand causing uneven boreAfter honing has been completed inspect all port opening areas for rough or sharp edgesApply slight chamfer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust portspiston-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 clearance