2004 Ski-Doo REV Series Factory Service Manual, Page 141Get this manual
Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT)
ENGINE DIMENSION MEASUREMENT
This section covers all engine types
CYLINDER OUT OF ROUND
ENGINE TYPE All MAXIMUM 0.08 mm (.003 in)
CYLINDER HEAD WARPAGE
ENGINE TYPE MAXIMUM 0.05 mm (.002 in) per 50 mm (2 in) of surface 0.5 mm (.020 in) for total length of cylinder head
Measuring 16 mm (58 in) from top of cylinder with cylinder gauge, check if the cylinder out of round is more than the specified dimensionIf larger, cylinder should be rebored and honed or should be replacedNikasil cylinder can be honed using diamond hone but cannot be reboredNOTE: Be sure to restore the chamfer around all cylinder sleeve port openings
Check gasketed surface of the cylinder head with straightedge and feeler gauge