2010-2012 PRO-RIDE RUSH Switchback RMK Service Manual, Page 111Get this manual
EngineCoolingExhaust Cylinder HeadCylinderPiston Notes Piston Matrix
Engine Model
S4139-8044-OO8G S4229-8044-OO8G S4092-8044-OO8G S4360-8044-OL8G S4361-8044-OL8G S4359-8044-OL8G
NOTE: Leave the exhaust Y-pipe attached to the cylinder assemblyRemove Y-pipe after removing cylinder from crankcase9Loosen all, then remove the cylinder boltsClean the bolt threads to remove any thread locking residue10Carefully pull the cylinder upwards taking care not to drop the pistons and rods abruptly against the crankcase11Remove the cylinder base gasketUse gasket scraper to clean the gasket residue from the crankcase and cylinder base12Inspect the cylinder wallsNicasil cylinders can only be lightly honed using 320 grit stoneDamage that cannot be removed with light hone requires cylinder replacement or re-chroming13Inspect the crankcase and cylinder mating surfaces for warping14The assembly process is the reverse of disassembly15Always use new gaskets and o-rings during assemblyLiberally coat the inside of each cylinder bore and the outside of each piston with Polaris twostroke engine oil16Always refresh the cylinder crosshatch pattern using 320 grit stoneSee "Cylinder Honing" on page 3.1417When installing piston into cylinder, verify each piston ring opening is located at each piston ring locating pinSqueeze the top ring, then carefully slide the cylinder over the compressed ringDo the same with the bottom ring18Follow the torque specifications and torque sequences located at beginning of chapter when tightening fasteners