Polaris 2003 Pro X Service Manual

HIGH PERFORMANCE

SERVICE MANUAL

Foreword

This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely andcorrectly. The technician should read the text and befamiliar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary importance.

All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position.

This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 440 PRO X Fan, 440 PRO X, 600 PRO X, 700 PRO X, 800 PRO X Polaris snowmobiles. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area.

At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice.

Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340.

High Performance Snowmobile Service Manual (PN 9918053)

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or property damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Willwood, Trademark of the Willwood Corporation Walker Evans Racing Shocks, Trademark of the Walker Evans Ent.

Foreword

Welcome to the 2002--2003 Polaris Racing season! Thank you for selecting Polaris as your racing vehicle.

The enclosed technical information, which is based on our past experience, should be reviewed by your team for machine preparation. Do not feel that these suggestions are a must, but use them as a starting point. This information has been outlined with reference to the sections in our 2002 Snowmobile Service Manuals. You will want to refer to them regularly to ensure correct procedures are followed.

The section index enables the user to quickly locate the component unit section desired. A table of contents is placed at the beginning of each chapter to aid the user in locating general areas of information. Keep this manual available for reference.

In order to provide you with the best support possible, Polaris racing, engineering, and testing department personnel must have timely and accurate data from the field. The weekly racing report form is a valuable source of this data. As a part of the Polaris team, your input is highly valued and

At Polaris, we are committed to your racing effort. We wish you the best of luck in the season ahead!

Please visit our website for updated information throughout the racing season.

never

ignored.

When at the home page (http://www.polarisindustries.com) click on “Snowmobiles” and then “Racing” for updated infromation throughout the race season.

Race Support Contacts

POLARIS RACING

10303 Calumet Ave. Suite#3 Mosinee, WI 54455 Phone: (715) 355--5157 Contact: Tom Rager Jr. EXT 11

Bill Rader EXT 12

Fax: (715) 355--8797

Parts Support

Dennis Weinke

Phone: (715) 355--3008

PRO X Introduction 1.1...................................

Initial Break--In 1.1.......................................

Trail Use Set Up 1.2.....................................

Publication numbers 1.3..................................

Specifications:

440 PRO X Fan 1.4 -- 1.5......................................

440 PRO X 1.6 -- 1.7..........................................

600 PRO X 1.8 -- 1.9..........................................

700 PRO X 1.10 -- 1.11..........................................

800 PRO X 1.12 -- 1.13..........................................

Bolt Size Guide 1.14......................................

Decimal Equivalent Chart 1.15.............................

Conversion Table 1.16....................................

Tap Drill Charts 1.17......................................

Glossary of Terms 1.18--1.21....................................

Tool List 1.22.............................................

Recommended Maintenance Products 1.23..................

GENERAL INFORMATION

PRO X Introduction

Polaris’ new Pro X models have been designed and tested to endure the toughest of all races. Many hours, days and months of testing have gone into development, and engineering has decided to use a predetermined weight rider and snow cross racing for stock setup. After uncrating your machine, be sure to test ride so setup can be determined for your mobile.

1. Stock suspension setup for the PRO X units is geared to a 170 lb (77.18 kg) pro rider.

2. Stock carburetion, clutching and gearing is for 0-3000 ft. (0-900 m).

3. In this manual, there are numerous optional springs, optional carburetor jets, optional clutch weights, and optional gears to suit your riding preference and location. When changing to optional parts, always test what you have done. Do not be afraid to experiment.

4. Be sure to use good quality traction products and pattern to maximize your traction and safety.

Break-in

The new PRO X units are high performance snowmobiles, and break-in is a vital step to ensure the performance of your machine will be at its peak.

riding style and characteristics. The following are setup tips for your brand new Pro X snow-

1. Always break-in any new part for 50-75 miles before using it for racing.

2. Clutch springs and belts need to be broken in to reach their peak in performance.

3. On the 440 Pro X, always use the correct type of fuel for the timing system you are using.

4. Pre mix 20:1 on break in and 32:1 after break in on the 440 Pro X liquid only.

5. Always use the recommended Polaris oil for your snowmobile.

6. Always break-in a new or rebuilt engine to ensure durability.

7. Maintain your exhaust valves frequently to ensure they are operating to their fullest capability.

Two--Cycle Engine Fuel / Oil ratio chart

To figure out the correct fuel to oil ratio per gallon, you will need to use the formula below:

Example of a Fuel/Oil Ratio of 20:1

128 (ounces of fuel in a gallon) y 20 (for the ratio)= 6.4oz. of oil needed for 1 gallon of fuel.

The correct way to mix the oil and fuel together is to have a fuel container 1/2 full of the amount of fuel that you are wanting to mix. Weigh the oil in a plastic cup to the desired weight ratio, and empty it into the fuel container and mix. Then empty the remaining fuel into the container and mix thoroughly once more.

Two--Cycle Engine Fuel / Oil Ratio Chart

Gallons of

Engine Fuel

1 6 4

2 13 8

3 19 12

4 26 16

5 32 20

6 38 24

20:1 32:1

1.1

GENERAL INFORMATION

ltitude

Below34

C-34t

o-23C-23t

o--12C-12t

o--1

C-1to+10CAbove+10

Meter

1200180

340#3320#3310#3290#2280#2270

(

)

0#3300#39

0#20#26

0#25

0#38

0#20#25

0#20#20

0#26

0#25

0#23

0#20#20

Trail Set Up

All 2003 440 Pro X Liquid units that are sold for trail use will need to have Head Kit PN 2202188 installed before the customer rides the sled. This Head Kit is designed to run on Premium 92 octane non--oxygenated fuel. To keep the warranty valid, this Head Kit must be in place on the 440 Pro X Liquids that will be sold for trail use. The 440 Pro X Liquid comes stock with a high compression head that requires 110 Octane fuel. If the head is not changed for Premium 92 octane fuel, engine

damage will occur. Warranty claims will not be accepted for damage that occurs on trail use 2003 440 Pro X Liquid models if this procedure is not performed.

NOTE: Head assembly PN 2202188 is not legal for ISR sanctioned race use.

Parts Required: Kit--92 Octane Cylinder Head PN 2202188

All parts required to perform this installation are included with kit PN

2202188. Parts included are (1) Head PN 3021343, O--ring PNs

5411199, 5411359, 5411411, Rubber Seal PN 5411465, Thermostat Gasket PN 5830113, and clutch weights for use at 0--3000 ft (3) PN

1321730. Please follow the instructions, clutching, and jetting

recommendations included in the kit.

kit and are not warrantable

Please install this Head Kit PN 2202188 on all 440 Pro X Liquid models that will be used for trail riding.

Jets are not included in this

The installation of this kit must be performed by an authorized Polaris dealer.

2003 440 Pro X 92 Octane Jetting Chart

AMBIENT TEMPERATURE

Altitude

Meters

(Feet)

0-- 600

(0-- 2000)

600-- 1200

(2000-- 4000)

1200-- 1800

(4000-- 6000)

1800--2400

(6000--8000)

2400--3000

(8000--10000)

3000--3700

(10000--12000)

Below -3 0qF Below -3 4qC

380

360

340 320 310 290 280 270

320 300 290 270 260 250

290 280 270 250 240 220

270 260 250 230 220 200

-30_ to --10_F

-34_to -23_C

360

340

-- 1 0 _to +10_ F

-23_ to --12_C

350

330

+10_to +30 _F

-12_to --1 _C

340

320

+30_to +50 _F

-1_to +1 0_C

320

300

Above +50_F Above +10_C

310

290

1.2

Publication Numbers

GENERAL INFORMATION

Model Model No.

440 Pro X Fan S03NX4FS 9917620 9917817 9917818

440 Pro X S03NX4CS 9917619 9917815 9917816

600 Pro X S03NX6ES 9917621 9917819 9917820

700 Pro X S03NX7CS 9917622 9917821 9917822

800 Pro X S03NX8CS 9917623 9917823 9917824

Owner’s Manual

Supplement

Parts

Manual

Parts

Microfiche

2003 Snowmobile Owner ’s Manual (All) - 9917436

2003 Service Manuals

2000--2003 120 XC SP 9918046

Trail Sport

Super Sport, 340 EDGE, 340 Classic, 500, 440 PRO X FAN

Touring

Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 500 Classic Touring, 600 Classic Touring, 700 Classic Touring

Frontier

Frontier Classic, Frontier Touring

Trail Luxury

340 Classic EDGE, 500 Classic, 550 Classic, 600 Classic, 700 Classic

Deep Snow

Trail RMK, 600/700/800 RMK, 700/800 SKS

Performance

500 XC, 500/600/700/800 XC SP, 800 XCR

High Performance

440 PRO X FAN, 440, 600, 700, 800 PRO X

Wallcharts 9918054

Track Poster 9918459

9918048

9918047

9918050

9918049

9918051

9918052

9918053

1.3

GENERAL INFORMATION

ltitude

Below34

34t

o-23C-23t

o--12C-12t

o--1

C-1to+10CAbove+10

Meter

1200180

320/310#3300/290#3290/280#3280/270#2270/260#1270/260

(

)

300/290#3280/270#3270/260#2260/250#2250/240#1250/240

280/270#3260/250#2250/240#2240/230#1230/220#1230/220

60/50#20/3

0#230/

0#20/0#10/0

0#10/0

ltitude

Shift

Clutc

Drive

haincas

d/S

Meter

0-900

Alm

ond

Silve

R49

1--4174P

d/S

900-180

Alm

ond

Silve

R49

1--4174P

d/S

180

0-270

Alm

ond

Silve

R49

1--4174P

d/S

270

0-370

Alm

ond

Silve

R49

1--4174P

MODEL: 440 PRO X Fan..........

MODEL NUMBER: S03NX4FS. ENGINE MODEL: EC45PM040..

CARBURETION

Type VM34AL Mikuni................

Main Jet 330 PTO/320 MAG............

Pilot Jet 40.............

Jet Needle 6HEY34--3...........

Needle Jet Q-2(286)...........

Cutaway 3.0............

Air Screw 0.75 Turns...........

Starter Jet 1.5...........

Valve Seat 1.5 Viton...........

Fuel Octane (R+M/2) 87 Non-Oxygenated.

89 Oxygenated

Throttle Gap

Under Cutaway .281s -(7.14mm)......

CLUTCH

Type P-85................

Belt 3211078.................

Belt Width (Projected) 1.438s. Side Angle (Overall) 28q.. Outside Circumference 46.625s

Center Distance 11.50s......

Shift Weights S--55........

Primary Spring Almond Red.......

Secondary Spring Silver/Blue....

Driven Helix R49 #3.........

Altitude

Meters

(Feet)

JETTING CHART

Below -3 0qF Below -3 4qC

0-- 600

(0-- 2000)

600-- 1200

(2000-- 4000)

1200-- 1800

(4000-- 6000)

1800--2400

(6000--8000)

2400--3000

(8000--10000)

3000--3700

(10000--12000)

360/350#4340/330#3330/320#3320/310#3310/300#2310/300

340/330#3320/310#3310/300#3300/290#3290/280#2290/280

320/310 300/290 290/280 280/270 270/260 270/260

300/290

280/270

260/250

XXX

CLUTCH CHART

Altitude

Meters

(Feet)

AMBIENT TEMPERATURE

-30_ to --10_F

-34_to -23_C

280/270

260/250

240/230

- # refers to the clip position from top of jet needle.

-- 1 0 _to +10_ F

-23_ to --12_C

270/260

250/240

230/220

+10_to +30 _F

-12_to --1 _C

260/250

240/230

220/210

DRIVE DRIVEN

Shift Clutch Clutch Driven

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

Weight

S--55 H

S--53 H

10 AL

Spring

Almon

Red

Almon

Red

Almon

Red

Almon

Red

Spring

ilver R4

Blue

ilver R4

Blue

ilver R4

Blue

ilver R4

Blue

+30_to +50 _F

-1_to +1 0_C

250/240

230/220

210/200

Helix

#-3

#-4

Above +50_F Above +10_C

250/240

230/220

210/200

Chaincase

Gearing

21-- 41 74P

HYVO

21-- 41 74 P

HYVO

21-- 41 74 P

HYVO

21-- 41 74 P

HYVO

ENGINE

Type Fan Cooled Cylinder Reed.......................

Displacement 438 cc...............

Bore 2.579s (65.5mm).......................

Stroke 2.559s (65mm).....................

Piston / Cylinder Clearance 0.0028s - 0.0041s (0.070 - 0.105 mm)...

Piston Marking 4RD..............

Piston Ring Marking 4N.........

Piston Ring End Gap 0.012 - 0.018 (.3 - .45 mm)........

Operating RPMr200 7750 RPM.........

Idle RPMr200 1600 RPM..............

Engagement RPMr300 5300 RPM......

Cylinder Head Torque 18-19 ft.lbs (2.5-2.8 kg-m)........

Cylinder Base Nut Torque 24-28 ft.lbs (3.3-3.9 kg-m)....

Crankcase Torque (8mm) 17-18 ft.lbs (2.2-2.3 kg-m).....

Crankcase Torque (10mm) 23-25 ft.lbs (3.2-3.5 kg-m)...

Flywheel Torque 60-65 ft.lbs (8.3-9 kg-m).............

1.4

GENERAL INFORMATION

MODEL: 440 PRO X Fan..........

MODEL NUMBER: S03NX4FS. ENGINE MODEL: EC45PM040..

ELECTRICAL CAPACITIES

Flywheel I.D. IG3792 Fuel Tank 11.8 Gal. (45.4 L)...... ..........

CDI Marking CU7235 Oil Tank 3.5 Quarts (3.3 L)....... ............

Alternator Output 240 Watts @ 4000 RPM Coolant N / A... ............

Ignition Timing 28q BTDC@3000RPMr1.5q Chaincase Oil 8 oz...... .......

9q BTDC@75000RPMr1.5q

Spark Plug / Gap NGK BR9ES / 0.028” (0.7mm)...

Lights: Head 2 60 High/55 Low......

Tail 2@3 watts........

Brake 18 watts......

Voltage Regulator LR7..

Electric Start N/A.......

SUSPENSION / CHASSIS CHAINCASE

Body Style Pro X Sprockets / Chain 21:41, 74 P HYVO........ ...

Front Suspension Pro X Reverse Option.. ............

IFS Shocks Ryde FXt Brake Pads HayesType 81........ .........

IFS Spring Rate 90/180#/in. Chaincase Center Dist.7.92” (20.12cm.)....

Front Spring Preload 2.8s Thread Adjust Driveshaft Sprockets 2 Drivers.

Front Vertical Travel 9.22s (23.4 cm..) Brake Type Polaris HPB.........

Rear Suspension Pro X...

Rear Travel 13.9s (35.3 cm..)........

Front Track Shock Ryde FX t..

Spring Rate 190#/in.........

Rear Track Shock Ryde FXt IFP Clicker..

Rear Springs .347s /77q......

Track Type 15sx121sx.82s (38.1x307.34x2.08cm..)........

Track Tension

OPTIONAL REAR TORSION SPRINGS

1 1/2” (38mm) slack with 10# (4.54kg) weight 16” (40.64cm..) ahead of rear idler shaft......

440 Pro X Fan Rear Torsion Springs

SOFT (STD) FIRM

.347s(sq.) diameter/77q .347s(sq.) diameter/77q .359s(sq.) diameter/77q

L.H . 7042159-- 067 L.H. 7042101-067 L.H. 7042157--067

R.H. 7042160--067 R.H. 7042102--067 R.H. 7042158--067

1.5

GENERAL INFORMATION

ltitude

Below34

34t

o-23C-23t

o--12C-12t

o--1

C-1to+10CAbove+10

Meter

1200180

280#3270#3260#3240#2230#2220

(

)

260#3250#3240#2230#2210#2200

0#23

0#20#20#20

0#29

0#20#20

0#29

0#28

0#20

ltitude

Shift

Clutc

Drive

haincas

d140

/20

070

Meter

0-900

Alm

ond

140/200

70/44

19:43

d140

/20

070

900-180

Alm

ond

140/200

70/44

19:43

d140

/20

070

180

0-270

Alm

ond

140/200

70/44

19:43

d140

/20062/40

270

0-360

Alm

ond

140/200

62/40

19:43

MODEL: 440 PRO X..........

MODEL NUMBER: S03NX4CS. ENGINE MODEL: S2424--4460PA4C..

CARBURETION

Type TMX-34 Mikuni................

Main Jet 290............

Pilot Jet 35.............

Jet Needle 6GL67--61--3...........

Needle Jet Q-8 (Fixed)...........

Cutaway 2.5............

Air Screw .5 Turns...........

Valve Seat 1.5 Viton...........

Starter Jet 1.5...........

Fuel Octane w/o Ethanol 110 Oct.minimum Throttle Gap

Under Cutaway .098s(2.5 mm)......

Exhaust Valve Spring Red/White

CLUTCH

Type P--85................

Belt 3211080.................

Belt Width (Projected) 1.438s (34.93mm). Side Angle (Overall) 28q.. Outside Circumference 46.625” (118.43cm..)

Center Distance 11.5s (305mm)......

Shift Weights S--51H........

Primary Spring Almond/Red.......

Secondary Spring Red/Blue 140/200....

Driven Helix 70/44 -- .46.........

(66/44 -- .46)

Altitude

Meters

(Feet)

JETTING CHART FOR 110 OCTANE

AMBIENT TEMPERATURE

0-- 600

(0-- 2000)

600-- 1200

(2000-- 4000)

1200-- 1800

(4000-- 6000)

1800--2400

(6000--8000)

2400--3000

(8000--10000)

3000--3700

(10000--12000)

Below -3 0qF Below -3 4qC

XXX

-30_ to --10_F

-34_to -23_C

310

300

280 270 260 240 230 220

260 250 240 230 210 200

240 230 220 210 200 190

230 210 200 190 180 170

- # refers to the clip position from top of jet needle.

300

280

-- 1 0 _to +10_ F

-23_ to --12_C

290

270

+10_to +30 _F

-12_to --1 _C

280

260

+30_to +50 _F

-1_to +1 0_C

270

250

Production=290 Main jet for 0_F at 0-- 1000 feet w/110 Octane non--ethanol fuel, the key switch is removed or in the110 octane position, and the timing curve in position “D”.

CLUTCH CHART

DRIVE DRIVEN

Altitude

Meters

(Feet)

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3600

(9000-12000)

Shift Clutch Clutch Driven

Weight

S-- 51H

S-- 49H

S-- 47H

S-- 45H

Spring

Almon

Red

Almon

Red

Almon

Red

Almon

Red

Spring

Red/Blue

Helix

.46

Above +50_F

Above +10_C

Chaincase

Gearing

19:43

74P

19:43

74P

19:43

74P

19:43

74P

260

240

ENGINE

Type Liquid Cooled Case Reed w/V.E.S........................

Displacement 438 cc...............

Bore 2.598s (66mm).......................

Stroke 2.520s (64mm).....................

Piston / Cylinder Clearance 0.0023s - 0.0037s(0.06 - 0.095mm)...

Service Limit 0.0059s (0.15mm)................

Piston Marking EK2185/28..............

Piston Ring Marking 3021303.........

Piston Ring End Gap .012s-.018s(.30-.45mm)........

Operating RPMr200 8500 RPM.........

Idle RPMr200 1500 RPM..............

Engagement RPMr300 5500 RPM......

Cylinder Head Torque 20-24 ft.lbs(2.8-3.3 kgm)........

Cylinder Base Nut Torque 30-34 ft.lbs(4.15-4.7 kgm)....

Crankcase Torque (8mm) 20-24 ft.lbs(2.8-3.3 kgm).....

Crankcase Torque (10mm) N/A...

Flywheel Torque 90 ft.lbs(12.4 kgm).............

1.6

GENERAL INFORMATION

MODEL: 440 PRO X..........

MODEL NUMBER: S03NX4CS. ENGINE MODEL: S2424--4460PA4C..

ELECTRICAL CAPACITIES

Flywheel I.D. 4010629 Fuel Tank 5 Gal. (18.9 L)...... ..........

CDI Marking 4010861 Oil Tank N/A (PRE MIX 32:1)....... ............

Alternator Output 280 Watts Coolant 4 Quarts (3.78 L)... ............

Ignition Timing 12q BTDC@1750RPM in “D” CurveChaincase Oil 9 oz...... .......

.with pipe sensor unplugged Spark Plug / Gap Champion RN-57YCC / 0.025” (0.64mm) PN 3070190...

Lights: Head 2 60High/55Low......

Tail 2@2 watts........

Brake 1@17 watts......

Voltage Regulator T1..

Electric Start N/A.......

SUSPENSION / CHASSIS CHAINCASE

Body Style PRO X Sprockets / Chain 19:43--74 P HYVO........ ...

Front Suspension PRO X Reverse N/A.. ............

IFS Shocks Walker Evans Alum IFP Brake Pads Hayes Type 81........ .........

Comp Adjust w/ Res. Chaincase Center Dist.7.92” (20.12cm.)...................

IFS Spring Rate 74/165#/in. Driveshaft Sprockets 2 Drivers-wide.... .

Front Spring Preload 3.75s Thread Adjust Brake Type Hayes.........

Front Vertical Travel 9.22s (23.42 cm.) Rear Suspension PRO X...

Rear Travel 13.90s (35.31 cm..)........

Front Track Shock Walker Evans Alum IFP..

Comp Adjust w/ Res....................

Spring Rate 160#/in.........

Rear Track Shock Walker Evans Alum IFP..

Comp Adjust w/ Res....................

Rear Springs .347s (sq.) / 77q......

Track Type 14sx121sx1.625s (35.6 x 307.34 x 4.12cm..)........

Track Tension

OPTIONAL REAR TORSION SPRINGS

11/2s (38mm) slack with 10# (4.54kg) weight 16s (40.64cm..) ahead of rear idler shaft......

440 Pro X Rear Torsion Springs

SOFT (STD) FIRM

.347s(sq.) diameter/77q .347s(sq.) diameter/77q .359s(sq.) diameter/77q

L.H 7042159-067 L.H. 7042101-067 L.H. 7042157-067

R.H. 7042160-067 R.H 7042102-067 R.H. 7042158-067

1.7

GENERAL INFORMATION

ltitude

Below34

34t

o-23C-23t

o--12C-12t

o--1

C-1to+10CAbove+10

Meter

1200180

420#2400#2390#2370#1350#1330

(

)

0#2380#2360#13

0#1330#13

0#2350#1330#13

0#1300#18

0#1330#13

0#19

0#10#16

ltitude

Shift

Clutc

Drive

haincas

ue/Red/

Meter

0-900

DarkBlue/

Red/Dar

8--42/

3-3974P

ue/Red/

900-180

DarkBlue/

Red/Dar

8--42/

3-3974P

ue/Red/

180

0-270

DarkBlue/

Red/Dar

8--40/

2-3974P

ue/Red/

270

0-370

DarkBlue/

Red/Dar

8--40/

2-4074P

MODEL: 600 PRO X..........

MODEL NUMBER: S03NX6ES. ENGINE MODEL: S2392--6044PA6E..

CARBURETION

Type TM 38 Mikuni w/TPS................

Main Jet 440............

Pilot Jet 40.............

Jet Needle 9DFH1-60-2...........

Needle Jet P-8...........

Cutaway 2.0............

Air Screw N/A...........

Valve Seat 1.5 Viton...........

Fuel Octane (R+M/2) 87 Non-Oxygenated.

89 OxygenatedKey Switch Adj.

Throttle Gap

Under Cutaway .079s (2.0mm)......

Pilot Air Jet .9..........

Starter Jet 140...........

Fuel Screw 1.5 Turns..........

Exhaust Valve Spring Green/Yellow.

CLUTCH

Type P-85................

Belt 3211080.................

Belt Width (Projected) 1.438s (36.52mm). Side Angle (Overall) 28q.. Outside Circumference 46.625s

Center Distance 11.50s......

Shift Weights 10-58........

Primary Spring Dark Blue/White.......

Secondary Spring Red/Dark Blue....

Driven Helix Team 58--42 /.46.........

Altitude

Meters

(Feet)

JETTING CHART

Below -3 0qF Below -3 4qC

0-- 600

(0-- 2000)

600-- 1200

(2000-- 4000)

1200-- 1800

(4000-- 6000)

1800--2400

(6000--8000)

2400--3000

(8000--10000)

3000--3700

(10000--12000)

XXX

CLUTCH CHART

Altitude

Meters

(Feet)

AMBIENT TEMPERATURE

-30_ to --10_F

-34_to -23_C

480

450

420 400 390 370 350 330

400

370

340

- # refers to the clip position from top of jet needle.

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

460

430

380

350

330

-- 1 0 _to +10_ F

-23_ to --12_C

440

410

360

330

310

DRIVE DRIVEN

Shift Clutch Clutch Driven

Weight

Dark Bl

10-58

Dark Bl

10-56

Dark Bl

10-54

Dark Bl

Spring

White

+10_to +30 _F

-12_to --1 _C

420

400

340

320

290

Spring

Dark

Blue

Dark

Blue

Dark

Blue

Dark

Blue

+30_to +50 _F

-1_to +1 0_C

Helix

400

380

330

300

270

-- 4 2

.46

-- 4 2

.46

-- 4

.46

-- 4

.46

Above +50_F Above +10_C

390

360

320

280

260

Chaincase

Gearing

23-39 74P

HYVO

23-39 74P

HYVO

22-39 74P

HYVO

22-40 74P

HYVO

ENGINE

Type Liquid Cooled Case Reed w/VES.......................

Displacement 593cc Fuel Pump Manuf. N/A............... .....

Bore 3.041s (77.25mm) Fuel Pump Mark N/A....................... .......

Stroke 2.520 (64mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance .0045s-.0059s (.11-.15mm) Oil Pump Mark 2540097... ........

Piston Marking 3021308 Cylinder Head Mark 3021320.............. ....

Piston Ring Marking N/A.........

Piston Ring End Gap .014s-.020s (.38-.51mm)........

Head ccs (Uninstalled) N/A.......

Head ccs (Installed) N/A.........

Operating RPMr200 8000.........

Idle RPMr100 1200..............

Engagement RPMr200 4000......

Cylinder Head Torque 20-24 ft.lbs. (28-33 Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24 ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) N/A...

Flywheel Torque 90 ft.lbs. (124 Nm).............

1.8

- Production Setting

GENERAL INFORMATION

MODEL: 600 PRO X............

MODEL NUMBER: S03NX6ES...

ENGINE MODEL: S2392--6044PA6E....

ELECTRICAL CAPACITIES

Flywheel I.D. 4010677 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010715 Oil Tank 3.25 quarts (3.1 liters)....... ............

Alternator Output 280 Watts Coolant 4 quarts (3.8 liters)... ............

Ignition Timing 24q BTDC@3500RPMr500 RPM Chaincase Oil 11 fl. oz.(325cc)/..... .......

With TPS unplugged w/Reverse13fl.oz (384cc)

0.1350s

3.430mm

Spark Plug / Gap Champion RN57YCC / 0.025s (0.64mm)... Voltage Regulator T1..

Electric Start N/A.......

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style PRO Xt Sprockets / Chain 23:39-74P HYVO........ ...

Front Suspension PRO Xt Reverse Option.. ............

IFS Front Shocks Alum IFP Brake Pads Type 81... .........

IFS Spring Rate 90/180#/in. Chaincase Center Dist.7.92s (20.12cm..)....

Front Spring Preload 2.75s Thread Adjust Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 9.22s (23.4cm..) Brake Type Polaris HPB, Liquid Cooled.........

Rear Suspension PRO Xt... Rear Axle Travel 13.86”(35.2cm..)... Front Track Shock Ryde FX IFP w/ R/R..

Spring Rate 160#........

Rear Track Shock Ryde Fx IFP R/R (Preload 1.75”).. Rear Torsion Springs .359s (sq.) / 77q

Track Type 15sx121sx1s (38.1x307.34x2.54cm..)........

Track Tension 3/8s -1/2s (1-1.3 cm..) slack with 10# (4.54kg) weight 16s (40.64cm..) ahead of rear......

idler shaft.

Overall Snowmobile Length 110s (279cm..).................

Overall Snowmobile Height 46s (117cm..).................

Maximum Snowmobile Width 48s (122cm..)...............

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347s(Sq.) Diameter x 77q .359s(Sq.) Diameter x 77q .405s(Sq.) Diameter x 77q

L.H. 7042101-067 L.H. 7042157--067 L.H.7042240--067

R.H. 7042102-067 R.H. 7042158--067 R.H.7042240--067

1.9

GENERAL INFORMATION

ltitude

Below34

C-34t

o-23C-23t

o--12C-12t

o--1

C-1to+10CAbove+10

Meter

1200180

420#3400#3390#3370#2350#2330

(

)

400#3380#3360#2340#2330#2310

0#3350#2330#23

0#2300#28

0#2330#23

0#29

0#20#26

ltitude

Shift

Clutc

Drive

haincas

Meter

0-900

lack/

2--42/

5--4176P

900-180

lack/

2--42/

5--4176P

180

0-270

lack/

2--40/

3-3974P

270

0-370

lack/

2--40/

3-3974P

MODEL: 700 PRO X..........

MODEL NUMBER: S03NX7CS. ENGINE MODEL: S2378--7070PA7C..

CARBURETION

Type TM40 Mikuni................

Main Jet 440............

Pilot Jet 45.............

Jet Needle J8--9DGN5--57--3...........

Needle Jet P-8...........

Cutaway 1.5............

Fuel Screw 2.25 Turns..........

Valve Seat 1.8...........

Fuel Octane (R+M/2) 87 Non-Oxygenated.

89 Oxygenated

Throttle Gap

Under Cutaway .0787s (2.0mm)......

Starter Jet 145...........

Pilot Air Jet N/A..........

Air Screw 1.25 Exhaust Valve Spring Green/Yellow.

CLUTCH

Type P-85................

Belt 3211080.................

Belt Width (Projected) 1.438s (36.52mm). Side Angle (Overall) 28q.. Outside Circumference 46.625s

Center Distance 11.50s......

Shift Weights 10-62........

Primary Spring Black / Green.......

Secondary Spring Black/Red....

Driven Helix Team 62--42/.46.........

Altitude

Meters

(Feet)

JETTING CHART

Below -3 0qF Below -3 4qC

0-- 600

(0-- 2000)

600-- 1200

(2000-- 4000)

1200-- 1800

(4000-- 6000)

1800--2400

(6000--8000)

2400--3000

(8000--10000)

3000--3700

(10000--12000)

XXX

CLUTCH CHART

Altitude

Meters

(Feet)

AMBIENT TEMPERATURE

-30_ to --10_F

-34_to -23_C

480

450

420 400 390 370 350 330

400

370

340

- # refers to the clip position from top of jet needle.

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

460

430

380

350

330

-- 1 0 _to +10_ F

-23_ to --12_C

440

410

360

330

310

DRIVE DRIVEN

Shift Clutch Clutch Driven

Weight

10-62

10-60

10-58

10-56

Spring

Black Green

+10_to +30 _F

-12_to --1 _C

420

400

340

320

290

Spring

Black

Red

Black

Red

Black

Red

Black

Red

+30_to +50 _F

-1_to +1 0_C

400

380

330

300

270

Helix

2--42

.46

2--42

.46

2--4

.46

2--4

.46

Above +50_F Above +10_C

Chaincase

Gearing

25-- 41 76P

HYVO

25-- 41 76P

HYVO

23-39 74P

HYVO

23-39 74P

HYVO

390

360

310

280

260

ENGINE

Type Liquid Cooled Case Reed Twin.......................

Displacement 701cc Fuel Pump Manuf. N/A............... .....

Bore 3.1889s (81mm) Fuel Pump Mark N/A....................... .......

Stroke 2.6772s (68mm) Oil Pump Manuf. Mikuni..................... .......

Piston / Cylinder Clearance 0.0047s - 0.0060s (0.12 - 0.15mm) Oil Pump Mark 2540102... ........

Service Limit 0.0060” (0.15mm) Cylinder Head Mark 3021342................ ....

Piston Marking 3021307..............

Piston Ring Marking N/A.........

Piston Ring End Gap .012mm........

Head ccs (Uninstalled) 37cc.......

Head ccs (Installed) 29.5 -- 30.5cc.........

Operating RPMr200 8100 RPM.........

Idle RPMr200 1400 RPM..............

Engagement RPMr200 3500 RPM......

Cylinder Head Torque 18-22 ft.lbs. (25-30 Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (8mm) 20-24 ft.lbs. (28-33 Nm).....

Crankcase Torque (10mm) 26-30 ft.lbs. (36-42 Nm)...

Flywheel Torque 90 ft.lbs. (124 Nm).............

1.10

- Production Setting

GENERAL INFORMATION

MODEL: 700 PRO X..........

MODEL NUMBER: S03NX7CS. ENGINE MODEL: S2378--7070PA7C..

ELECTRICAL CAPACITIES

Flywheel I.D. 4010677 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010749 Oil Tank 3.25 quarts (3.1 liters)....... ............

Alternator Output 280 Watts Coolant 4 quarts (3.8 liters)... ............

Ignition Timing 18q BTDC@2750RPMr1.5q Chaincase Oil 11 fl. oz.(325cc)..... .......

with TPS unplugged.

0.0815”

2.0705mm

Spark Plug / Gap Champion RN57YCC / 0.025s (0.64mm)... Voltage Regulator T1..

Electric Start N/A.......

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style PRO X Sprockets / Chain 25:41-76 P HYVO........ ...

Front Suspension PRO X Reverse Option.. ............

IFS Shocks Alum IFP/Threaded Brake Pads Type 81........ .........

IFS Spring Rate 90/180#/in. Chaincase Center Dist 7.92s (20.12cm..)....

Front Spring Preload 2.75s Thread Adjust Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 9.22s (23.4cm..) Brake Type Polaris HPB, Liquid Cooled.........

Rear Suspension PRO Xt... Rear Axle Travel 13.86”(35.2cm..)... Front Track Shock Ryde FX IFP w/ R/R (Preload 1.75”)..

Spring Rate 160#........

Rear Track Shock Ryde Fx IFP R/R.. Rear Torsion Springs .359s (sq.) / 77q

Track Type 15sx121sx1s (38.1x307.34x2.54cm..)........

Track Tension 3/8s -1/2s (1-1.3 cm..) slack with 10# (4.54kg) weight 16s (40.64cm..) ahead of rear......

idler shaft.

Overall Snowmobile Length 110s (279cm..).................

Overall Snowmobile Height 46s (117cm..).................

Maximum Snowmobile Width 48s (122cm..)...............

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347s(Sq.) Diameter x 77q .359s(Sq.) Diameter x 77q .405s(Sq.) Diameter x 77q

L.H. 7042101-067 L.H. 7042157--067 L.H.7042240--067

R.H. 7042102-067 R.H. 7042158--067 R.H.7042240--067

1.11

GENERAL INFORMATION

ltitude

Below34

C-34t

o-23C-23t

o--12C-12t

o--1

C-1to+10CAbove+10

120

0--180

430#4410#4400#3380#3360#3340#3(

Feet

)

ltitude

Shift

Clutc

Drive

haincas

Meter

0-900

2--46/

5-4076P

900-180

2--46/

5-4176P

180

0-270

2--44/

3-3974P

270

0-370

2--44/

3-3974P

MODEL: 800 PRO X..........

MODEL NUMBER: S03NX8CS. ENGINE MODEL: S2398--8070PA8C..

CARBURETION

Type TM 40 Mikuni................

Main Jet 450............

Pilot Jet 45.............

Jet Needle J8--9DGN5--57/4...........

Needle Jet P-8...........

Cutaway 2.0............

Fuel Screw 1.75 Turns Out..........

Valve Seat 1.8...........

Fuel Octane (R+M/2) Key Switch Adj..

91 Premium 89 Regular

Throttle Gap

Under Cutaway .0787s (2.0mm)......

Starter Jet 135...........

Pilot Air Jet N/A..........

Air Screw 1.5...........

Exhaust Valve Spring Pink/Yellow

CLUTCH

Type P-85................

Belt 3211080.................

Belt Width (Projected) 1.438s (36.52mm). Side Angle (Overall) 28q.. Outside Circumference 46.625s

Center Distance 11.50s......

Shift Weights 10-64........

Primary Spring Black/Green.......

Secondary Spring Black/Red....

Driven Helix Team 62--46/.46.........

Altitude

Meters

JETTING CHART

Below -3 0qF

Below -3 4qC

0-- 600

(0-- 2000)

600-- 1200

(2000-- 4000)

1200-- 1800

(4000-- 6000)

1800--2400

(6000--8000)

2400--3000

(8000--10000)

3000--3700

(10000--12000)

XXX

CLUTCH CHART

Altitude

Meters

(Feet)

AMBIENT TEMPERATURE

-30_ to --10_F

-34_to -23_C

490

460

430 410 400 380 360 340

410

#4 #3 #3 #3 #3 #2

380

#3 #3 #3 #3 #2 #2

350

#3 #3 #3 #2 #2 #2

- # refers to the clip position from top of jet needle.

470

440

390

360

330

-- 1 0 _to +10_ F

-23_ to --12_C

450

420

370

340

320

+10_to +30 _F

-12_to --1 _C

430

410

350

320

300

+30_to +50 _F

-1_to +1 0_C

410

390

330

310

280

Above +50_F

Above +10_C

400

370

320

290

260

DRIVE DRIVEN

Helix

2--4

.46

2--4

.46

2--44

.46

2--44

.46

Chaincase

Gearing

25-40 76P

HYVO

25-41 76P

HYVO

23-39 74P

HYVO

23-39 74P

HYVO

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

- Production Setting

Shift Clutch Clutch Driven

Weight

10-64 Black/Green Black/Red

10-62 Black/Green Black/Red

10-60 Black/Green Black/Red

10-58 Black/Green Black/Red

Spring

ENGINE

Type Liquid Cooled Case Reed Twin Fuel Pump Manuf. N/A....................... .....

Displacement 794cc Fuel Pump Mark N/A............... .......

Bore 3.3464s (85mm) Oil Pump Manuf. Mikuni....................... .......

Stroke 2.7559s (70mm) Oil Pump Mark 2540102..................... ........

Piston / Cylinder Clearance 0.006s - 0.0074s (0.15 - 0.188mm) Cylinder Head Mark 3021324... ....

Service Limit 0.0074” (0.188mm)................

Piston Marking 3021184..............

Piston Ring Marking N/A.........

Piston Ring End Gap 0.016s - 0.022s (0.41 - 0.56mm)........

Head ccs (Uninstalled) 45.7r0.5cc.......

Head ccs (Installed) 32.2r0.5cc.........

Operating RPMr200 8000 RPM.........

Idle RPMr200 1400 RPM..............

Engagement RPMr200 3800 RPM......

Cylinder Head Torque 18-22 ft.lbs. (25-30 Nm)........

Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm)....

Crankcase Torque (10mm) 26-30 ft.lbs. (36-41 Nm)...

Flywheel Torque 90 ft.lbs. (124 Nm).............

1.12

GENERAL INFORMATION

MODEL: 800 PRO X..........

MODEL NUMBER: S03NX8CS. ENGINE MODEL: S2398--8070PA8C..

ELECTRICAL CAPACITIES

Flywheel I.D. 4010677 Fuel Tank 11.8 gallons (44.7 liters)...... ..........

CDI Marking 4010750 Oil Tank 3.25 quarts (3.1 liters)....... ............

Alternator Output 280 Watts Coolant 4 quarts (3.8 liters)... ............

Ignition Timing 29q BTDC@3500RPM Chaincase Oil 11/13 fl. oz.(325cc)..... .......

with TPS unplugged

0.2146s

5.4510mm

Spark Plug / Gap Champion RN57YCC / 0.025s (0.64mm)... Voltage Regulator T1..

Electric Start N/A.......

Magneto Pulses 6....

SUSPENSION / CHASSIS CHAINCASE

Body Style PRO X Sprockets / Chain 25:40-76 P HYVO........ ...

Front Suspension PRO X Reverse Option.. ............

IFS Shocks Alum IFP/Threaded Brake Pads Type 81........ .........

IFS Spring Rate 90/180#/in. Chaincase Center Dist 7.92s (20.12cm..)....

Front Spring Preload 2.75s Thread Adjust Driveshaft Sprockets 2 Drivers Wide.

Front Vertical Travel 9.22s (23.4cm..) Brake Type Polaris HPB, Liquid Cooled.........

Rear Suspension PRO Xt... Rear Axle Travel 13.86”(35.2cm..)... Front Track Shock Ryde FX IFP w/ R/R (Preload 1.75”)..

Spring Rate 160#........

Rear Track Shock Ryde Fx IFP R/R.. Rear Torsion Springs .359s (sq.) / 77q

Track Type 15sx121sx1s (38.1x307.34x2.54cm..)........

Track Tension 3/8s -1/2s (1-1.3 cm..) slack with 10# (4.54kg) weight 16s (40.64cm..) ahead of rear......

idler shaft.

Overall Snowmobile Length 110s (279cm..).................

Overall Snowmobile Height 46s (117cm..).................

Maximum Snowmobile Width 48s (122cm..)...............

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347s(Sq.) Diameter x 77q .359s(Sq.) Diameter x 77q .405s(Sq.) Diameter x 77q

L.H. 7042101-067 L.H. 7042157--067 L.H.7042240--067

R.H. 7042102-067 R.H. 7042158--067 R.H.7042240--067

1.13

GENERAL INFORMATION

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

(MM/Thread)

Torque in. lbs.

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

Torque ft. lbs. (Nm)

1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................

1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............

5/16 - 18 11 (15) 17 (23) 25 (35).............. ................ ..............

5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............

3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............

3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............

7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............

7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............

1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............

1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............

*To convert ft. lbs. to Nm multiply foot pounds by 1.382. *To convert Nm to ft.lbs. multiply Nm by .7376.

(Nm)

1.14

1/64 .0156..........................

1/32 .0312 1 mm = .0394s..................... ..................

3/64 .0469..........................

1/16 .0625...............

5/64 .0781 2 mm = .0787s.......................... ..................

3/32 .0938.....................

7/64 .1094 3 mm = .1181s......................... ..................

1/8 . .1250.. ........

9/64 .1406..........................

5/32 .1563 4 mm = .1575s..................... ..................

11/64 .1719.........................

3/16 .1875 5 mm = .1969s............... ..................

13/64 .2031.........................

7/32 .2188.....................

15/64 .2344 6 mm = .2362s......................... ..................

1/4 .25...........

17/64 .2656 7 mm = .2756s......................... ..................

9/32 .2813.....................

19/64 .2969.........................

5/16 .3125 8 mm = .3150s............... ..................

21/64 .3281.........................

11/32 .3438 9 mm = .3543s.................... ..................

23/64 .3594.........................

3/8 .375...........

25/64 .3906 10 mm = .3937s......................... ..................

13/32 .4063....................

27/64 .4219 11 mm = .4331s......................... ..................

7/16 .4375...............

29/64 .4531.........................

15/32 .4688 12 mm = .4724s.................... ..................

31/64 .4844.........................

1/2 .5 13 mm = .5118........... .....................

33/64 .5156.........................

17/32 .5313....................

35/64 .5469 14 mm = .5512s......................... ..................

9/16 .5625...............

37/64 .5781 15 mm = .5906s......................... ..................

19/32 .5938....................

39/64 .6094.........................

5/8 .625 16 mm = .6299s........... ...................

41/64 .6406.........................

21/32 .6563 17 mm = .6693s.................... ..................

43/64 .6719.........................

11/16 .6875..............

45/64 .7031 18 mm = .7087s......................... ..................

23/32 .7188....................

47/64 .7344 19 mm = .7480s......................... ..................

3/4 .75...........

49/64 .7656.........................

25/32 .7813 20 mm = .7874s.................... ..................

51/64 .7969.........................

13/16 .8125 21 mm = .8268s.............. ..................

53/64 .8281.........................

27/32 .8438....................

55/64 .8594 22 mm = .8661s......................... ..................

7/8 .875...........

57/64 .8906 23 mm = .9055s......................... ..................

29/32 .9063....................

59/64 .9219.........................

15/16 .9375 24 mm = .9449s.............. ..................

61/64 .9531.........................

31/32 .9688 25 mm = .9843.................... ..................

63/64 .9844.........................

11.0............

GENERAL INFORMATION

1.15

GENERAL INFORMATION

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs.

in. lbs. x .0833 = ft. lbs.

ft. lbs. x 1.382 =Nm

in. lbs. x .0115 =kg-m

Nm x .7376 = ft.lbs.

kg-m x 7.233 = ft. lbs.

kg-m x 86.796 =in.lbs.

kg-m x10 =Nm

in. x 25.4 =mm

mm x .03937 =in.

in. x2.54 = cm..

mile (mi.) x1.6 =km

km x .6214 = mile (mi.)

Ounces (oz) x 28.35 = Grams (g)

Grams (g) x 0.035 = Ounces (oz)

lb. x .454 =kg

kg x 2.2046 =lb.

Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)

Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)

Imperial pints (Imp pt) x 0.568 = Liters (l)

Liters (l) x1.76 = Imperial pints (Imp pt)

Imperial quarts (Imp qt) x 1.137 = Liters (l)

Liters (l) x0.88 = Imperial quarts (Imp qt)

Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)

US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)

US quarts (US qt) x 0.946 = Liters (l)

Liters (l) x 1.057 = US quarts (US qt)

US gallons (US gal) x 3.785 =Liters (l)

Liters (l) x 0.264 = US gallons (US gal)

Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)

Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)

Kilopascals (kPa) x0.01 = Kilograms - force per square cm..

Kilograms - force per square cm.. x 98.1 = Kilopascals (kPa)

qCtoqF: 9 (qC + 40) y 5--40=qF qFtoqC: 5 (qF + 40) y 9--40=qC

1.16

GENERAL INFORMATION

SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size

#0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64

1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 11/4-7 17/64 1 1/4-12 1 11/64 11/2-6 111/32 1 1/2-12 1 27/64 13/4-5 19/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 21/2-4 21/4 23/4-4 21/2 3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1 .50 12 x 1.50 12 x 1.75

#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

1.17

GENERAL INFORMATION

ACV: Alternating current voltage.

Air Gap Spark Test: A good check for ignition voltage and general ignition system condition. Spark should arc 3/8” (1

cm..) minimum from end of high tension lead to ground. Several testers are available commercially.

Alternator: Electrical generator producing alternating current voltage.

Bore: Diameter of cylinder.

BTDC: Before Top Dead Center.

Bump Steer: When skis toe in and toe out through suspension travel.

CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a

capacitor or condenser (in CDI box). At the proper moment a voltage generated by the statorplate pulser coil closes an electronic switch (thermistor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of the ignition coil.

Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends.

Center Distance: Distance between center of crankshaft and center of driven clutch shaft.

Chain Pitch: Distance between chain link pins. Polaris measures chain length in number of pitches.

Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven

clutch.

Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face as the engine torques back.

Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close.

Coil: A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field passes through it.

Combustion Chamber: Space between cylinder head and piston dome at TDC.

Compression: Reduction in volume or squeezing of a gas.

Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems.

Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO. Maximum allowable run-out is .006” (.02 cm..).

DCV: Direct current voltage.

Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks

“hammered” through, rough appearance around hole. Possible causes: 1) too high a compression ratio for the fuel octane; 2) low octane fuel; 3) over-advanced ignition timing; 4) lean fuel/air mixture.

Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.

Displacement: The volume of the cylinder displaced by the piston as it travels from BDC to TDC. The formula is:

Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port.

Electrical Open: Open circuit. An electrical circuit which isn’t complete. (i.e. poor connections or broken wire at hi-lo

beam switch resulting in loss of headlights.

Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended component. (i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake lights).

End Seals: Rubber seals at each end of the crankshaft.

Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.

E.T. Ignition: Energy Transfer ignition. Generates primary ignition voltage through electro magnetic induction.

Bore x Stroke x 3.1416

= Displacement in CCs

1.18

GENERAL INFORMATION

Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk.

Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.

g: Gram. Unit of weight in the metric system.

Head Volume: Cylinder head capacity in cc, head removed from engine with spark plug installed.

Heat Exchanger: A device used to transfer heat. Mounted under running boards, they dissipate engine heat to the

atmosphere.

Hex Head Bolt: Standard type of wrench-applied hexagon head, characterized by clean, sharp corners trimmed

to close tolerances. Recommended for general commercial applications.

Hi-Fax: Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of the suspension rails.

High Side: Sled pushes or tips up.

High Tension Wire: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.

Hole Shot: A term used when machine starts a race from a dead stop.

Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2) pre-ignition.

Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher voltage

in the secondary windings (approx. 14KV - 32KV) through inductions. Secondary voltage is high enough to arc the air gap at the spark plug.

Ignition Generating Coil: Exciter coil, primary charge coil. Stator plate coil which generates primary ignition voltage. CDI system uses one ignition generating coil. Twin cylinder E.T. ignition systems use two ignition generatingcoils. Coil is mounted at the top of the stator plate.

Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

Kg/cm..2: Kilograms per square centimeter. Metric equivalent of PSI.

Keystone Ring: A piston ring with bevel on upper inside surface.

Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.

Metric equivalent of ft. lbs.

L Ring: A wide face piston ring with an ”L” shaped cross section. Leg of ”L” goes up when installing on piston.

Labyrinth Seal: A pressure type center seal identified by series of grooves and lands. Polaris engines us this type of

seal to separate the cylinders in the crankcase halves.

Left Side: Always referred to based on normal operating position of the driver.

Lighting Coil: Generates voltage for lights, battery charging, etc by electromagnetic induction.

Loose: When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently.

mm: Millimeter. Unit of length in the metric system. 1mm = .040”.

Mag End: Flywheel side of engine.

Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, ignition generating coils and trigger coil.

Ohm: The unit of electrical resistance opposing current flow.

Oval Head Screw: Fully specified as ”oval countersunk”, this head is identical to the standard flat head, but

possesses a rounded upper surface for attractiveness of design.

PTO End: Power Take Off drive (clutch side).

Pan Head Screw: Provides a low, large diameter head, but with characteristically high outer edges along the

outer edge ofthe head wheredriving action ismost effective. Slightly different headcontour when supplied with Phillips Recess. See dotted line.

Piston Clearance: Total distance between piston and cylinder wall.

Piston Erosion: Piston domemelts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuel/air mixture;

2) improper spark plug heat range.

1.19

GENERAL INFORMATION

Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks

melted at area of damage. Possible causes: 1) too hot a spark plug; 2) spark plug not properly torqued; 3) “glowing” piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean fuel/air mixture; 5) Incorrect ignition timing.

Primary Circuit: This circuit isresponsible for the voltagebuild up in the primarywindings of thecoil. Partsof this circuit include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition coil. In the CDI system the parts include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the low resistance primary windings in the ignition coil.

Primary Clutch: Drive clutch on engine.

Primary Compression: Pressure built up in the crankcase of a two stroke engine.

psi.: Pounds per square inch.

Pushing: When the front of the vehicle does not steer as much as the driver desires. The skis do not grab sufficiently.

R&R: Remove and replace.

RFI: Radio Frequency Interference. Caused by high voltage from the ignition system. There are special plug caps and

spark plugs to help eliminate this problem. Required in Canada.

RPM: Revolutions Per Minute.

Relay Coils: Electromagnetic device inan EFI system which controls circuit connection with input from another circuit.

Resistance: In the mechanicalsense, friction or load. In the electrical sense, ohms. Both result inenergy conversionto

heat.

Right Side: Always referred to based on normal operating position of the driver.

Round Head Screw:The familiar head most universally used for general application. Good slot depth, ample

underhead bearing surface and finished appearance are characteristic of this head.

Running Time: Ignition timing when fully advanced or at specified RPM.

Secondary Circuit: This circuit consists of the large secondary coil windings, high tension wire and ground through the

spark plug air gap.

Secondary Clutch: Driven clutch on chaincase or jackshaft.

SeizedPiston: Galling of the sides of apiston. Usually there is a transfer of aluminum from the piston onto the cylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.

Self Steer: Pulling the machine to the inside of the track.

Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4” (2 cm..) reach plugs.

Static Timing: Ignition timing when engine is at zero RPM.

Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coils. Stroke: The maximum movement of the piston from bottom dead center to top dead center. It is characterized by 180q

of crankshaft rotation.

Surge Tank: The fill tank in the liquid cooling system.

TDC: Top Dead Center. Piston’s most outward travel from crankshaft.

Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine.

Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI

systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.

V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM increases.

Venturi: An area of air constriction. A venturi is used incarburetors to speedup air flowwhich lowerspressure in venturi to below atmospheric pressure, causing fuel tobe pushed throughjets, etc., and into the venturi to be mixed with air and form a combustible air/fuel mixture.

Vol t: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.

Watt: Unit of electrical power. Watts = amperes x volts.

1.20

GENERAL INFORMATION

Service

In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual, thoroughly familiarizing him/herself with procedures before beginning. Pictures and illustrations have been included with the text asan aid. Notes, cautions andwarnings havealso been included for clarification oftext and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily. Use only genuine Polaris service parts.

Cleanliness of parts and tools as well as the work areais of primary importance. Dirt and foreign matter will act as an abrasive and cause damageto precision parts. Clean the snowmobile before beginning service. Clean new parts before installing.

Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with gloves when working with sharp components.

If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.

Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid damage to fasteners.

Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead toserious machine damage or, as in the case of steering components, can result in injury or death for the rider(s).

If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten. Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before removing them.

If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks.

Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms these parts, they should always be replaced with new parts. When installing new retaining rings andclips use care not to expand or compress them beyond what is required for installation.

Because removal damages seals, replace any oil or grease seals removed with new parts.

Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.

Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses lubricity and may contain abrasive foreign matter.

Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and get prompt medical attention.

1.21

GENERAL INFORMATION

Tool List

Tool Part Number Description

2870338 Drive Clutch Spider Nut Socket

2870426 P--85 CLutch Offset Alignment Tool 5/8”

8700220 Clutch Compression Tool

PS--45909

2870576 Drive Clutch Bore Tapered Reamer

2870910 Roller Pin Tool

2870974 Jackshaft Installer

2871173 Primary Clutch Compressor

2871296 Jackshaft Installer

2872085 Clutch Puller (3/4--16 x 14mm)

2872401 20mm C--Clip Tool

2872987 Spider Remover/Installer

PS--45259 Gas Fill Tool & Gauge

PS--45259-- 1 Gas Fill Needles (20 Pack)

PS--45260 Lower Retainer Wrench

PS--45261 IFP Positioning/Extraction Tool

PS--45262 Cylinder Head Wrench

PS--45263 Wear Band Tool

PS--45152 THIN Rear Suspension Wrench

PS--45909 High Performance Driven Clutch Compression Tool

PS--45908 T--Handle Walker Evans IFP Tool

PS--45629 Body Clamps for Walker Evans 1 3/4”

2871358 Clutch Holding Fixture

9314177--A Clutch Holding Wrench

PS--45484 Rivet Punch (To remove self--piercing rivets)

PS--45678 Shock Shaft Seal Protector (.51 diameter shock shaft)

2201639 Shock Shaft Seal Protector (.498 diameter shock shaft)

2201640 Shock Shaft Seal Protector (.620 diameter shock shaft)

PU--45485 Exhaust Spring Removal Tool

2874522 Walker Evans Racing Shock Oil (5w)

TEAM Clutch Compression Tool Extensions (To be used with Clutch Com-

pression tool)

1.22

GENERAL INFORMATION

Recommended Maintenance Products

ENGINE OIL RETAINING/SEALING PRODUCTS

Part # Description

2871721 Synthetic 2-Cycle Premium Gold Quarts/ 6 2870652 Fuel Stabilizer 16 oz / 12

2871722 Synthetic 2-Cycle Premium Gold Gallon / 4 2872280 Fuel Stabilizer 2.5Gallon/2

2871723 Synthetic 2-Cycle Premium Gold 16 Gallon Drum 2871329 Nyogelt Grease 2oz

2871884 Synthetic 2 Cycle Premium Gold 55 Gallon Drum 2871064 T-9 Metal Protectant each

2871098 Premium 2-Cycle Oil (TC-W3) Quart Cans / 12 2870632 Metal Polish 10 oz / each

2871097 Premium 2-Cycle Oil (TC-W3) Gallon / 6 2871076 Battery Tendert each

2871240 Premium 2-Cycle Oil (TC-W3) 2.5Gallon/2 2870585 Primer N, Aerosol 25 gr / 1

2871566 Premium 2-Cycle Oil (TC-W3) 16 Gallon Drum 2870584 680 Retaining Compound 10cc / each

2871385 Premium 2-Cycle Oil (TC-W3) 30 Gallon Drum 2871949 Threadlock 242 50cc / 10

2871096 Premium 2-Cycle Oil (TC-W3) 55 Gallon Drum 2871950 Threadlock 242 6cc / 12

2872927 VES 2 Cycle Synthetic Oil Quart 2871951 Threadlock 262 50cc / 10

2872925 VES 2 Cycle Synthetic Oil Gallon 2871952 Threadlock 262 6cc / 12

2872924 VES 2 Cycle Synthetic Oil 55 Gallon Drum 2871953 Threadlock 271 6cc / 12

2872607 Nature Oil (TC-W3) Gallon 2871954 Threadlock 271 36cc / 6

2872926 Nature Oil (TC-W3) 55 Gallon Drum 2871955 Instant Adhesive: Prism 401 3cc / 30

MAINTENANCE PRODUCTS 2871956 Pipe Sealant 565 50cc / 6

2872435 Cross Shaft Break-in Lube 8oz/12 2871957 Silicone, Black RTV 3 oz tube / 12

2872436 Cross Shaft Break-in Lube 2.5 Gal / 2 2871958 Silicone, Black RTV 11 oz Cartridge/12

2871326 Carbon Clean Plus 12 oz / 12 2871959 UltraBlueRTV 3.35 oz / 12

2871280 Premium Chaincase Lubricant Quart / 12 2871960 UltraBlueRTV 13 oz Cartridge/12

2870464 Premium Chaincase Lubricant Gallon / 4 2871961 518 Flange Sealant 50cc / 10

2872281 Premium Chaincase Lubricant 2.5Gallon/2 CRANKCASE SEALANTS

2872951 Synthetic Chaincase Lubricant 12 oz. 2871557 3 Bond 1215 5oz

2873105 Synthetic Chaincase Lubricant Quart VALUE PACKS

2873106 Synthetic Chaincase Lubricant Gallon 2871967 Synthetic Lube Value Pack 4/Valuepack

2872952 Synthetic Chaincase Lubricant 2.5 Gallon 2871593 TC-W3 Lube Value Pack 4/Valuepack

2871323 Premium Antifreeze 60/40 Premix Gallon / 6 WAX AND POLISH

2871534 Premium Antifreeze 60/40 Premix Quart / 12 2871589 Revival/Detailing Kit 6 / Kit

2870995 Premium Gas Shock Oil Quart / 6 2871966 Restore polish/scuff remover 12 / 12 oz.

2872279 Premium Gas Shock Oil 2.5Gallon/2 2871965 Reflect Wax Final Finish 12 / 12 oz.

2870990 Premium Brake Fluid DOT-3 12oz / 12 2871964 Renew vinyl rubber protector 12 / 12 oz.

2870791 Premium Fogging Oil (spray) 12/12 oz RACING FUELS

2871517 Premium Fogging Oil (liquid with spout) Quart / 12 2873019 100 Octane 5 Gallon

2871518 Premium Fogging Oil (liquid) Gallon / 6 2872980 100 Octane 16 Gallon Drum

2871312 Grease Gun Kit (All Season) 3oz/4 2872981 100 Octane 55 Gallon Drum

2871322 Premium All Season Grease 24oz / 10 2873019 110 Octane 5 Gallon

2871423 Premium All Season Grease 143oz/ 2872982 110 Octane 16 Gallon Drum

2871460 Premium Starter Grease 2oz/12 2872983 110 Octane 55 Gallon Drum

2871592 Barrel Pump (for 16/30/55 gal. drums) Each

2871285 Flex Spout (fits gal. and 2.5 gal. jugs) 25

2870505 Isopropyl 10 oz / 24

Packaging

(size / quantity)

Part # Description

Packaging

(size/quantity)

1.23

Improvements and Specifications 2.1................

Torque Specifications 2.2...........................

Spark Plugs 2.2...................................

Torque Patterns 2.3................................

Formulas 2.4 -- 2.5......................................

VES System 2.6 -- 2.8...................................

440Pro X Timing 2.9...............................

440 Pro X Fan Engine Dissassembly 2.10 -- 2.16.............

440 Pro X Fan Engine Assembly 2.17 -- 2.22.................

440/600 Pro X Engine Dissassembly 2.23 -- 2.26.............

440/600 Pro X Engine Assembly 2.27 -- 2.32.................

700/800 Pro X Engine Dissassembly 2.33 -- 2.38.............

700/800 Pro X Engine Assembly 2.38 -- 2.42.................

VES Maintenance/Adjustment 2.43 -- 2.45...................

VES Optional Springs 2.46...........................

General Inspection Procedures 2.47 -- 2.49..................

Crankshaft Truing 2.50 -- 2.51..............................

Crankshaft Indexing 2.52............................

Exhaust Gas Tempurature 2.53.......................

Piston Wash / Spark Plug Color 2.54..................

Cylinder Head Inspection 2.55........................

Piston Inspection/Measurement 2.56..................

Oil Pump Operation/Inspection 2.57 -- 2.59...................

Cooling System Bleeding Procedures 2.60.............

Cooling System Exploded Views 2.61 -- 2.63.................

Troubleshooting 2.64................................

Improvements for 2003 440 Pro X

1. V--Forcet Reeds

2. Revised carburetion calibration

3. “Dragon” ignition system

ENGINE

V FORCEt REEDS

Pro X Model Specifications

Machine Model Engine Model Cyl.

Disp.

CC’s

440 Pro X Fan EC45PM040 438 65.5 2.579 65 2.559 2 Fan 87*

440 Pro X S2423--4460PA4C 438 66 2.598 64 2.520 2 Liquid 110**

600 Pro X S2392--6044PA6E 593 77.25 3.041 64 2.520 2 Liquid 87*

700 Pro X S2378--7070PA7C 701 81 3.189 68 2.677 2 Liquid 87*

800 Pro X S2398--8070P8C 794 85 3.346 70 2.756 2 Liquid 87*

* Non-oxygenated. Use minimum 89 octane when using oxygenated fuel. ** 110 Octane minimum.

Model Piston/Cylinder

440 Pro X Fan .07-.105 (.0028-.0041s) 7750 1600

440 Pro X .11--.15 (.0044--.0058) 8400 1500

600 Pro X .11-.14 (.0045-.0055s) 8000 1500

700 Pro X .11 (0.0044”) 8100 1400

800 Pro X .15 (0.006”) 8000 1400

Bore

Bore Clearance

+.05 mm

-- . 0 0 m m

(MM / Inch )

Bore

Inches

RPM ¦200

StrokeMMStroke

Engine

Operating

No. of

Inches

Recommended

Idle RPM

Cyl.

Type of Cooling

Fuel

Octane

(Min.)

2.1

ENGINE

When tightening bolts, nuts, or screws, a torque pattern should be followed to insure uniform equal tension is applied to all fasteners. Proper torque application prevents fasteners from looseningor breaking in criticalservice. It also minimizes wear and eliminates premature or needless repair costs. Following uniform torque application sequence patterns assures optimum performance from precision machined, close tolerance assemblies. On vital engine parts, torquing negligence could be costly.

Torque is a force which tends to produce rotation. Themeasurement of this force isexpressed in units of force and length. There are at present two basic systemsof units used to express torque, English and Metric. In the English system, the units of force are the pound or ounce, and the length is the foot or inch.

In the Metric system, the unit of force is expressed in grams (gm) or Newton meters (Nm), and length as centimeters (cm.) or meters (m). The most common units of torque in the English system are ft. lb. and in. lb. In the Metric system, torque is commonly expressed in units of Nm. Multiply foot pounds by 1.382 to obtain Nm.

See page 2.3 for engine torque sequences

Engine

EC-45 18-19 ft. lbs.

S44**

SN60-44** SN50** SN60-70**

SN70** SN80**

**Torque head bolts prior to torquing cylinder base nuts. Apply loctitet 242.

All 6mm Crankcase Bolts 108 in. lbs. (12.4 Nm).....

All 7/16-14 Engine Mount Strap Bolts 44-48 ft. lbs. (60-66 Nm).....

Cylinder Head* Cylinder

(25-26.5 Nm) 20-24 ft. lbs.

(28 - 33 Nm)

18-22 ft. lbs. (25 - 30 Nm)

Base Nuts

24-28 ft. lbs. (33-39 Nm)

30-34 ft.lbs (42-47 Nm)

Crankcase

8mm

17-18 ft. lbs. (22-23 Nm)

20-24 ft.lbs. (28 - 33 Nm)

Spark Plugs

Polaris Part

Number

3070156 NGK BR8ES

3070157 NGK BR7ES

3070160 NGK B7ES

3070161 NGK B8ES

3070162 NGK B9ES

3070163 NGK BR9ES

3070165 Champion RN2C

3070166 Champion RN3C

3070184 Champion RN57YC

3070190 Champion RN57YCC

3070198 NGK BR8EV

Spark Plug

Crankcase

10 mm

23-25 ft. lbs. (32-35 Nm)

N/A

26-30 Ft lbs (36-42 Nm)

Flywheel

60-65 ft. lbs. (83-90 Nm)

90 ft. lbs. (124 Nm)

2.2

ENGINE

6 7

CYLINDER HEAD

440/600 Pro X

CRANKCASE - 440/600 Pro X

1 4

CYLINDER BASE

440/600 Pro X

CYLINDER HEAD - Pro X Fan

CYLINDER HEAD

Libertyt 700 / 800

CYLINDER BASE Libertyt 700/800

CRANKCASE - Pro X

Fan

Libertyt Crankcase - 700 / 800

2.3

ENGINE

R = (IHV+DISP)

IHV

I= S

(DISP*25.4)

DISP = (PI*B*B*S)

IHV = INSTALLED HEAD VOLUME [CC] DISP= CYLINDER DISPLACEMENT [CC] R = COMPRESSION RATIO S = FULL ENGINE STROKE [CM] I = INCHES PER CC OF IHV B = CYLINDER BORE [CM] PI = 3.1416

Bore = 6.5 cm. Stroke = 6.0 cm. IHV = 17.1 cc

Displacement = SBore  Stroke



S 



Displacement = 199.098 cc

IHV + Displacement

R = 12.643

IHV

Full Stroke Compression Ratio

To calculate the Effective Compression Ratio, substitute the exhaust port height for the stroke in the formulas above:

Exhaust = 2.95 cm.

Eff Disp = SBore  Stroke



Exhaust port height 29.5 mm

Effective Displacement



Eff Disp = 97.89 cc

Eff Comp =

IHV + Eff Disp

IHV

Effective Compression Ratio

Eff Comp = 6.725

In order to increase the Full Stroke Compression Ratio to 13.6, how much material do you need to remove from the cylinder head?

You know that:

IHV + Displacement

IHV

, and you want to find out IHV.

Displacement = 199.098 cc, and we want R = 13.6, so then

IHV2 =

IHV2 = 15.801 cc desired IHV to have 13.6:1 Full Stroke Compression Ratio

2.4

Displacement

(R -- 1)

HEAD CC REMOVAL EXAMPLE

Total number of CCs to remove from the head = Old IHV -- Desired IHV

Removed CCs = IHV -- IHV2

Removed CCs = 1.299 cc

ENGINE

Displacement ô 2.54 ô

I = 0.01186 ô

To find out how much to cut off, multiply the number of CCs you need to remove by the number of inches to remove per CC:

Thickness to remove = I ô Removed CCs

Thickness to remove = 0.015 in

PORT OPENING DURATION

Port open = 81.5q

Stroke

Number of inches to remove from the

cm.

This indicates the degrees after TDC that the exhaust port opens (and also the degrees before TDC that the port closes).

cylinder head to equal 1 cc

Duration closed = 2 ô Port open

Duration closed = 163q

Total duration = 360q

Duration open = Total duration -- Duration closed

Duration open = 197q

Percent open =

Percent open = 54.722

Duration open

Total duration

ô 100

2.5

ENGINE

Variable Exhaust System (V.E.S.)

Some snowmobiles are equipped with the Polaris

This unique exhaust valve management system changes the effective exhaust port height in the cylinder to provide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange throttle settings.

Variable Exhaust System (V.E.S.)

Spring

Cover

Bellows

Housing

Exhaust Valve

In order to understand the operation and function of the V.E.S. we must first consider the characteristics of a two stroke engine. The height of the exhaust port in a two stroke enginecylinder has an affect on the total power output of an engine, as well as the RPM at which the power occurs.

Exhaust systems are “tuned” by design to match engine exhaust port configuration and desired power delivery characteristics. Engines with relatively “high” exhaust ports (and exhaust pipe to match) produce more horsepower at high RPM, but only at the expense of low to midrange fuel economy and torque. On the other hand, “low” port engines provide good fuel economy in the midrange and make their power at relatively lower RPM, but will not produce as much peak horsepower for a given displacement range. In general, an engine designed for a racing or high performance snowmobile will have a relatively high exhaust port compared to an engine of the same displacement range designed for touring.

Although the V.E.S. does not in itself increase horsepower, it does allow an engine to be designed for maximum horsepower without the inherent disadvantages of a high exhaust port.

The main components of the V.E.S. are the exhaust valve, valve housing, bellows, return spring, and cover.

A guillotine style exhaust valve is connected to a moveable piston. This piston is attached to a flexible bellows, forming two chambers. The lower chamber is connected to the cylinder by a drilled passageway located just above the exhaust port. The upper chamber is vented to atmospheric pressure. A valve return spring is located in the upper chamber between the piston and cover.

At idle and low speeds, the exhaust valve is held in the “low port” position by the return spring. When throttle is applied (and RPM begins to increase) rising cylinder pressure is applied to the under side of the bellows via the actuation port. This forces the exhaust valve upward against spring pressure. The valve continues to move upward toward the “High Port” position as cylinder pressure, horsepower, and RPM increase.

2.6

V.E.S. Maintenance

Due to the simplicity of V.E.S. design, maintenance is limited to a periodic inspection and cleaning of system components. The V.E.S. should be disassembled, inspected, and cleaned (remove carbon deposits) every 1000 to 2000 miles, depending on operating conditions. To ensure maximum performance and minimize required maintenance, Polaris recommends the use of Polaris Synthetic 2 Cycle lubricant only. The use of other lubricants may cause improper function of the valve mechanism, and increase the frequency of required cleaning due to excessive buildup of carbon deposits.

V.E.S. Removal and Cleaning

Removal and cleaning is covered later in this chapter.

V.E.S. Troubleshooting

Symptom Possible Cause Remedy

Engine will not reach designed operating RPM

Poor acceleration; hesitation; High RPM performance is normal or near normal

Valve not opening or not opening completely:

1. Exhaust valve sticking

2. Cylinder pressure feed port restricted

3. Bellows damaged or not sealing correctly

4. Incorrect spring

5. Problem in clutch setup, drive line, engine, etc.

Valve opening too early:

1. Valve sticking open or partially open

2. Broken, damaged, or incorrect, spring

Valve cover

Bellows

Washer

ENGINE

Adjuster nut

O-ring

Spring

Val ve cap

Bolt

Valve housing

Dowel pin

Gasket

Val ve

1. Remove carbon deposits, burrs etc.

2. Clean port

3. Inspect bellows, fastener straps, and gasket and repair as required

4. Inspect

5. Inspect

1. Clean, Inspect

2. Inspect, Replace

2.7

ENGINE

Variable Exhaust System (V.E.S.) - 440 Pro X

440 Pro X Variable Exhaust System:

The exhaust valve system on the new 440 Pro X is electronically controlled by solenoids. Pressure from the cylinders is routed through the solenoids to the atmosphere. During this time the exhaust valves are down. When the CDI senses 6700 RPM, it triggers the solenoids to shut off the bypassed air going to the atmosphere. Pressure then builds inside the exhaust valve bellows, causing the valves to fully open. When RPM drops below 6700, the solenoids open to allow air to bypass through to atmosphere and the exhaust valves close.

Solenoid

Open

T-Fitting

Inlet Hole

from Cylinder

Below 6700 RPM

CDI Box

Wire Wire

Hose

Balance Tube

Spring

Bellows

Exhaust Valves Closed

Yellow Wire to

Wiring Harness

Inlet Hole

from Cylinder

Hose

T-Fitting

Spring

Solenoid

Open

Bellows

Above 6700 RPM

Solenoid

Closed

Hose

T-Fitting

Inlet Hole

from Cylinder

CDI Box

Wire

Spring

Bellows

Exhaust Valves Fully Open

Yellow Wire to

Wiring Harness

Wire

Balance Tube

Inlet Hole

from Cylinder

Solenoid

Closed

Hose

T-Fitting

Spring

Bellows

Exhaust

Outlet Hole

Val ve

2.8

Exhaust

Val ve

Exhaust

Val ve

Outlet Hole

Exhaust

Val ve

ENGINE

Changing the Timing curve

CAUTION

This engine is jetted for operation at 0 degrees _F and warmer. Re-jetting is required for temperatures colder than 0_F.

The second switch islocated on the airbox andhas seven optionalcurves. These seven options are used tomatch the fuel type and the racing conditions which may vary, depending on the race. The standard position is “D” and should not be moved unless you are a knowledgeable engine tuner.

Position

A +3

B +2

C +1

D (Standard Position) 0

E -- 2

F -- 3

G -- 4

Timing Effect

2.9

ENGINE

Engine Disassembly - 440 Pro X Fan Engine

NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings, and gaskets with Genuine Polaris parts during assembly.

Disassembly

1. Remove coil pack from air box, and disconnect it from the wiring harness.

2. Loosen carburetor clamps and remove each carburetor.

3. Using a pliers, detach the oil lines from the carburetors.

2.10

Disassembly - Continued

4. Remove the carburetor mounting boots using a allen wrench.

ENGINE

5. Remove both the cylinder head and exhaust side fan shroud s from the engine assembly.

6. After removing the fan shrouds, take note of the vibration dampener located between the two intake ports.

2.11

ENGINE

Disassembly - Continued

7. Remove the CDI module from the flywheel cover.

8. Remove the flywheel cover.

9. Prior to removing the flywheel, insert a piece of nylon rope or cord into a spark plug hole. Rotate the crankshaft counter-clockwise until it will no longer turn over.

2.12

Disassembly - Continued

10. Remove the recoil cam.

11. Loosen and remove the flywheel nut.

ENGINE

12. Using a flywheel puller, remove the flywheel from the engine. Do not install puller bolts more than 5/16s (7mm) into flywheel threads or stator damage may result.

Flywheel Puller

PN 2871043

2.13

ENGINE

Disassembly - Continued

13. Remove the flywheel.

14. The stator plate can be removed without taking off the stator.

15. Remove the oil pump taking note of the o-ring and shim(s).

2.14

Disassembly - Continued

16. Remove the cylinder head.

17. Remove the head gasket. During removal, note that the head gasket is stamped with “EX” and “UP”.

ENGINE

18. Loosen and remove each cylinder.

2.15

ENGINE

Disassembly - Continued

19. Remove the reed valves from the crankcase.

20. Using an awl and piston pin puller, remove the pistons.

CAUTION:

Wear eye protection during piston c-clip removal to prevent eye injury.

Piston Pin Puller

PN 2870386

21. Turn crankcase over and remove the crankcase bolts. Turn over and separate the case halves.

22. Refer to General Inspection section for crankshaft inspection and measurement procedures.

2.16

Engine Assembly

1. Prior to assembly, make sure that you have all of the oil pump shims when the oil pump was removed, and that the shims are installed in the correct order.

ENGINE

2. Insert oil pump drive gear.

3. Insert oil pump driveshaft spacer.

2.17

ENGINE

Engine Assembly - Continued

5. Lay crankshaft into the lower case half. Make sure that the crankshaft rotates smoothly and does not bind. Rotate the bearings so that the anti-rotation pins rest in their appropriate galleries. NOTE: Lubricate the crankseal prior to installation.

6. Apply 3-Bond¥ sealer to top half of crankcase. Lubricate oil pump drive gear.

3-Bond ¥ 1215

PN 2871557 120 Gram Tube

7. Install the upper case half.

8. Turn the crankcase over and torque the case bolts in sequence illustrated in beginning of chapter.

Crankcase Bolt Torque

16.6 - 18 ft.lbs. (22 - 25 Nm)

2.18

Engine Assembly - Continued

9. Install pistons with arrow (") on piston facing flywheel, with locating pins to intake side. Install C-clips securely in piston groove. NOTE: C--Clip should be facing with the open end up.

10. Lubricate rings and pistons with two stroke oil. Install rings with letter, mark, or beveled side facing upward.

ENGINE

11. Install the reed valves in the crankcase. After installing the reed valves, insert the base gaskets.

12. Install each cylinder. Torque cylinder base nuts in sequence illustrated in beginning of chapter.

Cylinder Base Nut Torque 24 - 28 ft.lbs. (33 - 39 Nm)

2.19

ENGINE

Engine Assembly - Continued

13. Install the cylinder head gasket with the “EX” on the exhaust side, and “UP” on the intake side of the engine.

14. Insert the dowels into the flywheel housing.

NOTE: Refer to picture for proper installation of alignment dowels.

15. Tighten flywheel housing to crankcase.

2.20

Engine Assembly - Continued

16. Install the flywheel and insert the lock washer.

17. Torque the flywheel nut. During the procedure, use a flywheel holding wrench to prevent the flywheel from rotating.

ENGINE

Flywheel Holding WrenchPN 8700229

Flywheel Nut Torque 60 - 65 ft.lbs. (83 - 90 Nm)

18. Reinstall the flywheel cover.

2.21

ENGINE

Engine Assembly - Continued

19. Insert the vibration dampener into the cooling fins between the intake ports. Reinstall the two fan shrouds making sure that they interlock before fastening tightly.

20. Using a new o-ring, reinstall the oil pump.

Oil Pump Mounting Screw Torque:

48 - 72 in.lbs. (5.5 - 8.3 Nm)

21. Install each carburetor and torque the carburetor mounting clamps Reinstall oil lines on the oil pump.

2.22

ENGINE

NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, O-rings, and gaskets with Genuine Polaris parts during assembly.

Disassembly -- Liberty t 440 / 600 Liquid

1. Remove carburetor mount adaptors, reed cages, stuffers, and oil pump. Note position of stator wire guide. Measure air gap between fiber reed and reed block as shown. The air gap should not exceed .015s (.4 mm). If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap.

replace them if damaged.

white stress marks or missing material. Replace if necessary.

2. Remove V.E.S. (if applicable).

Check eachfiber reedfor

Always

Reed Pedal Clearance .015s (.38 mm) max.

Exaggerated for illustration

3. Remove cylinder head cover and inspect O-rings and sealing surfaces for damage or debris. Use new O-rings upon assembly.

2.23

ENGINE

Disassembly, Cont.

4. Remove cylinder base nuts. Note location of acorn nuts on exhaust side (where applicable).

5. Carefully remove cylinders while supporting pistons and connecting rods to prevent piston damage. Refer to General Inspection Procedures in this chapter.

6. Remove outer piston pin C-clips using a scribe through access slot in piston.

7. Place support block underpiston and remove piston pins using pin puller.

Piston Pin Puller PN 2870386

Support Block PN 2870390

8. Remove water pump cover from front of engine.

2.24

Disassembly, Cont.

9. Remove recoil housing and drive hub.

10. Remove flywheel using heavy-duty flywheel puller. Use drive clutch puller T-handle or a wrench to hold puller.

Flywheel Puller PN 2871043

ENGINE

T-Handle PN 5020326

11. Before removing stator plate, note where ignition timing marks are located, or scribe additional marks for reference upon reassembly.

12. Mark or note location of engine mount straps and remove.

2.25

ENGINE

Disassembly, Cont.

13. Remove bolts and separate case halves. Keep bolts in order for assembly.

14. To prevent damage to snap-ring grooves, lift crankshaft straight upward and out of lower case.

15. Tap out the drive shaft using a center punch and hammer. Locate the center punch in the centering hole on the oil pump end of the shaft. Be careful not to damage the bearing. This will remove the oil seal and the mechanical seal from the crankcase.

2.26

ENGINE

Assembly

1. Insert bushing into case on oil pump side of case. Press in until firmly seated in case.

2. Install the bearing washer to the oil pump end of the shaft. S Lubricate shaft, insert shaft through the case on water pump side into the bushing on oil pump

side.

3. Lubricate and install bearing washer and brass bushing onto the shaft on waterpump side.

NOTE: If front bushing is replaced it may be necessary to drill a retaining pin hole in the new bushing. If there is no hole in the bushing:

S Measure depth of the retaining pin hole in the old

bushing.

S Using the retaining pin hole as a guide, carefully drill

a hole in the new bushing to the same depth and diameter as the hole in the old bushing. Be careful not to enlarge the retaining pin hole, or drill too deep.

S Install new retaining pin.

4. Lubricate and install oil seal with seal lip out (towards you) until it is against the bushing.

Rear bushing

O--ring

Oil Pump side

Bearing Washers

Front Brass Bushing

Seal (Spring faces mechanical seal)

Align hole in bushing with weep hole and retaining bolt hole

Mechanical Seal

Impeller

Water Pump side

Flat washers

Nut

5. Lubricate and install new mechanical seal using the Mechanical Seal Guide Tool PN 2872010.

6. Press a new mechanical seal into case until fully seated.

Mechanical Seal Guide Tool 600 PRO X domestic engines 8.4mm: PN 2872010

2.27

ENGINE

Assembly, Cont.

7. Lubricate and install new mechanical seal using the Mechanical Seal Guide Tool PN 2872010.

8. Lubricate seal guide and drive or press a new mechanical seal into case until fully seated using the seal press tool.

9. Lubricate all crankshaft bearings with Premium 2-Cycle or Premium Gold Engine Lubricant.

10. Apply 1/3 oz. (10 cc) cross shaft break-in lube to oil pump gears.

Oil Pump Cross Shaft Break-in Lube: PN 2872435 - 8 oz. PN 2872436 - 2.5 Gallon

11. DO NOT insert any grease in the grease zerk located on the PTO end of the crankcase(440 Pro X engine only). Pack the crankcase PTO end cavity with 22 grams of Mobile 1 Synthetic grease.

12. Install seals on crankshaft with spring facing inward (toward crankshaft).

13. Clean and de-grease lower crankcase and install crankshaft assembly, aligning seals and snap ring with grooves in case.

14. Apply a thin coating of 3-Bond 1215 sealant to lower crankcase mating surface.

15. Install upper crankcase on lower crankcase.

16. Apply Loctite 242 to threads of bolts and install. Torque bolts in three steps to specification outlined in beginning of this chapter following the sequence shown at right

1 4

PTO EndMAG End

2.28

Assembly, Cont.

17. Assemble engine mount straps to crankcase.

Engine Mount Strap Torque:

44-48 ft. lbs. (60-66 Nm)

18. Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly.

19. Install a new C-clip in both pistons (inside) with gap facing down. Be sure clip is fully seated in groove.

20. Lubricate and install new connecting rod small end bearing in rod.

21. Install piston with arrow facing exhaust (ring locating pins should be facing intake). Warming the piston may help to ease installation of pin.

ENGINE

22. Install remaining C-clip with gap down. Be sureboth clips are fully seated in the groove.

23. Install new base gasket. Be sure gasket surface is clean and free of nicks, burrs, or scratches.

24. Lubricate andinstall piston rings on piston with mark on end of ring facing upward.

25. Place piston support under skirt and lubricate pistons and cylinders thoroughly.

26. Align ring end gaps with locating pins and compress rings. Install cylinder carefully with a gentle front to rear rocking motion. Install cylinder base nuts loosely. Do not tighten them at this time. Repeat Steps 22-25 for other cylinder.

CAUTION:

Do not twist or force cylinder during installation.

27. Install new cylinder head O-rings and install cylinder head. Make sure O-rings are properly seated in grooves. Apply a light film of grease to hold O-rings in place if necessary.

Straight Edge

Piston Ring Cutaway

Keystone Piston Ring

2.29

ENGINE

Assembly, Cont.

28. Install new cylinder head cover O-rings and install cylinder head cover. Make sure O-rings are properly seated in grooves. Apply a light film of grease to hold O-rings in place if necessary.

29. Loctite 242 to threads of head bolts and install.

30. Torque head bolts to specification outlined on page

2.3 of this chapter.

31. Torque cylinder base nuts outlined on page 2.3--2.4 of this chapter.

32. Install washers and water pump impeller as shown and torque nut to 10 ft. lbs. (14 Nm).

Impeller Nut Torque:

CYLINDER HEAD - 440 Pro X

MAG SIDE

Engine side

8 5

CYLINDER BASE

440 Pro X

Washer

10.3x14x1mm

10 ft.lbs. (14 Nm)

PTO SIDE

10 Ft lbs (14 Nm)

2.30

Mechanical Seal

Washer .325x.75x.063s

Assembly, Cont.

33. Install water pump cover with new gasket.

Water Pump Cover Bolt Torque:

9 Ft lbs (12.5 Nm)

34. Install new exhaust manifold gaskets and manifold.

Exhaust Manifold Bolt Torque:

16 Ft lbs (22 Nm)

35. Assemble V.E.S. valve. Refer to V.E.S. procedures on pages 2.36-2.39.

ENGINE

36. Install reed valves, stuffers, and carburetor adaptors. Place stator wire guide on Mag side carburetor adaptor bolt.

37. Install stator assembly, aligning timing marks or marks made upon disassembly. Seal stator wires with high temperature silicone sealant. Install and tighten stator screws to specification.

38. Measure trigger (pulse) coil gap and compare to specification.

Stator Screw Torque

60 in. lbs. (7 Nm)

Trigger (Pulse) Coil Gap

Minimum: .020s (.5mm ) Maximum: .040s (1.0mm )

Seal Stator Wires

Apply Loctitet 262 to Taper

2.31

ENGINE

Assembly, Cont.

39. Apply Loctitet 262 evenly to the flywheel mounting taper on crankshaft. Install woodruff key.

40. Install flywheel. Apply Loctitet 242 to crankshaft threads. Install washer and nut.

41. Use flywheel holder to hold flywheel and torque nut to specification found in beginning of this chapter.

Flywheel Holder:

PN 8700229

42. Install recoil hub and recoil housing. Torque bolts to specification.

Recoil Hub and Housing Bolt Torque:

108 in. lbs. (12.5 Nm)

43. Install engine in chassis and align clutches.

44. Refer to General Inspection Procedures in this chapter to fill and bleed cooling system and oil pump.

2.32

ENGINE

Libertyt 700 / 800 Engines

NOTE: Inspect all parts for wear or damage during disassembly. It is recommendedtoreplace all seals, O-rings, and gaskets with Genuine Polaris parts during assembly. Refer to General inspection procedures in this chapter.

Disassembly

1. Remove the oil pump.

2. Remove the recoil housing and the recoil hub. Inspect waterpump drive belt for missing, cracked, or broken drive cogs.

Measure the belt at 4 different points as shown. Replace if width is lessthan .250s, (6.35mm). Nominal new width is .345s, (8.75mm).

3. Remove drive gears and belt.

4. Remove flywheel nut using flywheel holder.

Flywheel Holder: PN 8700229....

Replace if width is less than .25s (6.35mm)

Flywheel Holder:

PN 8700229

2.33

ENGINE

Disassembly, Cont.

5. Remove flywheel using flywheel puller.

6. Note the ignition timing strip on the flywheel.

Flywheel Puller: PN 2871043

7. Before removing stator plate, mark the plate and crankcase for reference upon assembly.

8. Remove bolts holding water pump housing to crankcase. Loosen hose clamp and remove housing.

Hose Clamp

Timing strip

2.34

Disassembly, Cont.

9. Inspect water pump weep hole for signs of leakage or blockage.

10. Remove crankshaft seal from housing by driving seal to inside of housing. Replace seal if removed.

ENGINE

Inspect Weephole

11. Remove water pump cover bolts and then remove impeller nut. Slide shaft out back side.

12. Inspect bearings. Replace if necessary. Replace mechanical seal using the special tools listed below. Use the seal press to install a new mechanical seal in cover with spring sleeve toward impeller housing. Install seal guide over end of shaft and apply a light film of grease to seal guide. Carefully install shaft and bearings in cover. Assemble 10x14mm washer, impeller, washer, and nut. Torque impeller

nut to 10 ft.lbs. (14Nm).

Water Pump Mechanical Seal Installation

Tool - 700/800 domestic engines:

8.9mm.

PN 2872389

2.35

ENGINE

Disassembly, Cont.

13. Remove reed cover, reed stuffers, and reeds.

Reed Valve Inspection

14. Measure air gap between fiber reed and reed block as shown. The air gap should not exceed .015s (.4 mm). If clearanceis excessive DO NOT attempt to reverse the reeds to reduce the air gap.

Always replace them if damaged.

each fiber reed for white stress marks or missing material. Replace if necessary.

15. Remove V.E.S. assembly. Clean valves as outlined later in this chapter.

Check

Max Reed Pedal Clearance .015s (.38 mm).

Exaggerated for illustration

16. Remove cylinder head. Note condition and placement of cylinder head O-rings.

17. Loosen cylinder base nuts and remove cylinders.

2.36

Disassembly, Cont.

18. Carefully remove C-clip holding piston pin in place.

19. Remove piston pin using piston pin puller and adaptor.

Piston Pin Puller PN 2870386

Adaptor PN 5130971

ENGINE

20. Remove water manifold by removing both retainer brackets.

21. Remove bottom crankcase bolts and separate crankcase halves.

Remove Clamps

2.37

ENGINE

Disassembly, Cont.

22. Remove snap rings and crankshaft seals.

23. Clean thoroughly to remove all grease, oil, dirt, and old sealant.

Assembly

1. Clean all parts with solvent and dry with compressed air.

2. Apply 3-Bond¥ 1215 sealant to upper crankcase half.

NOTE: Use only 3-Bond¥ 1215 sealant. Curing time and film thickness are critical for proper bearing clearance.

3-Bond ¥ 1215

PN 2871557 120 Gram Tube

3. Set crankshaft in lower crankcase. Lubricate seal lips with Premium All Season Grease. Make sure seals are positioned properly with lip and spring facing inward toward crankshaft. Install snap rings with gap facing upward toward upper case half.

2.38

Assembly, Cont.

4. If studs were removed or new crankcase installed, apply Loctite¥ 242 to threads of studs and screw in until bottomed. Tighten securely.

5. Measure installed length of stud bolt. This is the length necessary to allow cylinder installation.

Lower Crankcase Stud Height

121-124 mm (4.76-4.88s) from crankshaft

parting line.

6. Install crankcase halves together. Torque bottom crankcase bolt to specification in the proper sequence found in the beginning of this chapter.

ENGINE

7. Install new O-rings on water manifold. Grease O-rings and install manifold.

8. Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly.

9. Install anew C-clip inboth pistons (inside) with gap facing up or down. Be sure clip is fully seated in the piston groove.

Replace O-rings

Gap Up

Gap Down

2.39

ENGINE

Assembly, Cont.

10. Lubricate and install new connecting rod small end bearing in rod.

11. Install remaining C-clip with gap up or down. Be sure both clips are fully seated in the groove.

C--Clip Installation Tool

PN 2872622 -- 22mm for Large Block

(700--800 Domestic Engines)

12. Install pistons and rings. Make sure C-clips are firmly seated in grooves. NOTE: Keystone ring bevel must be up. Marking near ring end gap faces upward.

13. Lubricate pistons, rings, upper rod bearing, and cylinders with two stroke oil and install cylinders. Align ring end gaps with locating pins and compress rings. Install cylinder carefully with a gentle front to rear rocking motion. Loosely install the cylinder nuts.

Straight Edge

Piston Ring Cutaway

Keystone Piston Ring

14. Install new cylinder head O-ring and install cylinder head. Make sure O-ring is properly seated in groove.

15. Torque cylinder base bolts in proper sequence. Refer to specifications in the beginning of this chapter.

2.40

Assembly, Cont.

16. Torque head bolts in proper sequence. Refer to specifications in the beginning of this chapter.

ENGINE

17. Reassemble water pump carefully installing seal.

18. Install crankcase seal to ignition/water pump housing from inside toward outside until bottomed on housing. Spring and seal lip must face inward toward crankshaft.

19. Apply 3 Bond¥ sealant to pump housing crankcase mating surface and carefully install onto crankcase. Tighten water pump to engine hose clamp and torque bolts to specification.

Ignition/Water Pump Housing Torque

22 Ft. lbs (30.4 Nm)

Install Seal

Apply 3-Bond

Hose Clamp

2.41

ENGINE

Assembly, Cont.

20. Align timing marks and install stator.

21. Install flywheel and torque flywheel nut to 90 ft.lbs (124Nm).

Flywheel Nut Torque -

90ft. lbs. (124 Nm)

22. Install water pump belt and recoil hub.

NOTE: See domestic twin water pump belt installation in chapter 2, Maintenance, for correct belt installation

Recoil Hub Bolt Torque -

96-108 in. lbs. (11 - 12.5 Nm)

23. Install recoil cover and oil pump. Make sure oil pump drive slot mates properly with water pump shaft.

24. Install reed valve, reed stuffer, and reed cover.

2.42

V.E.S. Removal

1. Remove the mounting bolts.

On Domestic Engines remove all four (4) mounting bolts and be ready to catch the spring and cover as you remove the mounting bolts.

CAUTION:Valve is spring loaded. Hold cover in position until all bolts are removed.

2. Remove exhaust valve assembly from the cylinder(s).

3. 800 Fuji engines, remove four cover bolts, cover, and return spring.

CAUTION:Valve is spring loaded. Hold cover in position until bolts are removed.

ENGINE

Domestic Twin Engines

4. If the spring stays in the cover, hold the cover with spring facing toward you. Rotate spring in a counterclockwise direction while pulling outward on the spring. Do not distort the spring upon removal.

5. Insert V.E.S. in a soft jawed vice. Carefully remove exhaust valve cap.

NOTE: Top nut is secured to valve with adhesive. Removing top nut may damage threads on valve. If nut will not loosen, apply a small amount of heat to cap. DO NOT OVERHEAT or damage to the bellows will result.

2.43

ENGINE

V.E.S. Disassembly, Cleaning, Inspection

1. Clean O-ring and bellows in warm water and

mild detergent. Inspect bellows for holes, distortion or damage. Replace if necessary. Inspect O-ring for damage.

2. Clean all other parts with solvent. Be sure all

parts are thoroughly clean.

3. Inspect the actuator port in cylinder and valve

housing. Be sure it is clear and not obstructed by debris or carbon.

Valve cover

Bolt

Spring

Val ve cap

Bellows

Washer

Valve housing

Gasket

Val ve

Clean with Solvent

4. Carbon deposits can be removed from valve

withaScotchBritet pad or similar soft abra- sive brush.

5. Lubricate exhaust valve with Polaris Premium

Gold 2-cycle engine lubricant. Install valve in cylinder and move it through the entire travel range to check for free movement without binding. If the valve sticks anywhere in the travel range, check the valve and valve bore in the cylinder for carbon deposits and clean if necessary. Do not remove anodized coating while cleaning.

Clean with Scotch Britet or similar soft abrasive brush

2.44

V.E.S. Assembly

1. Insert exhaust valve into valve housing. Re-

place housing gasket.

2. Install washer, beveled side out, and bellows.

ENGINE

3. Apply Loctitet 262 to the threads of valve

install valve cap. Torque to specification.

Valve Cap Torque:

6 Ft lbs (8.3 Nm)

4. Install spring, valve cover, and adjuster nut.

Torque exhaust valve cover bolts to specification.

Fuji Valve Cover Bolt Torque:

4 Ft lbs (5.5 Nm)

Domestic Valve Cover Bolt Torque:

12 ft.lbs(16Nm)

and

5. Install V.E.S. assembly onto cylinder and torque

V.E.S. housing bolts to specification. Domestic Engines utilize two of the cover bolts for mounting to the cylinder. The torque value for these are 12 ft.lbs(16Nm).

2.45

ENGINE

Polaris Variable Exhaust System Springs

PART NUMBER COLOR

7041786--01 RED/WHITE 3.0 4.3 1.854 .041

7041786--02 BLUE/WHITE 4.0 6.0 1.740 .045

7041786--03 GREEN/WHITE 5.0 7.0 1.930 .045

7041786--04 YELLOW/WHITE 5.0 8.0 1.620 .045

7041786--05 ORANGE/WHITE 7.0 9.0 2.300 .046

7041786--06 PINK/WHITE 6.0 8.0 2.110 .046

7041786--07 PURPLE/WHITE 9.0 11.0 2.670 .049

7041786--08 GREEN/YELLOW 8.0 10.0 2.400 .049

7041786--09 RED/YELLOW 3.0 3.7 2.586 .037

7041786--11 PINK/YELLOW 9.0 11.5 2.323 .051

7041704--01 BLUE 4.0 6.0 1.752 .0475

7041704--02 ORANGE 5.5 8.3 1.729 .0475

7041704--03 PINK 4.7 7.1 1.734 .046

7041704--04 PURPLE 3.1 4.7 1.726 .040

7041704--05 YELLOW 2.4 3.6 1.734 .037

7041704--06 WHITE 1.6 2.8 1.537 .036

LOAD @ 1.0 In

(LBS.)

LOAD @ .630 in

(LBS.)

FREE LENGTH

(REF)(IN.)

WIRE DIA.

(IN.)

These springs will change the timing characteristics of the exhaust valve opening. A heavier spring will keep the valve in the closed position longer, while a lighter spring will allow the valve to open sooner. NOTE: If making any changes to the valve springs make sure to change all springs so that each valve spring is the same.

Free Length Measurement

(for reference)

2.46

ENGINE

Cylinder Service

Maximum engine performance and easy starting are directly related to the compression of the fuel and air mixture in the combustion chamber. It is important that the cylinder walls are concentric, smooth and perpendicular to the crankshaft center line. All new engines have these characteristics built into them, however, the stresses and heat of operation may cause the bore to distort or score, resulting in loss of compression and power.

Inspection

A simple way of checking cylinder/piston condition is to remove the exhaust manifold and look into the exhaust port. If there is a considerable amount of blow by (brown or black carbon deposit) under the piston rings, the cylinder should be removed and honed. The piston rings should be replaced also.

The cylinder should always be inspected whenever an engine has been disassembled for repair or any time a loss of power or cylinder cranking compression is noted. A visual inspection after the cylinder head is removed will reveal if the cylinder should be removed for honing. Inspect for any scratches or signs of scoring or brown areas which indicate ring leakage and distortion.

Cylinder Honing

The cylinder bore must be de-glazed whenever new piston rings are installed*. A light honing with fine stones removes only a very small amount of material. A proper crosshatch pattern is important to provide a surface that will hold oil, and allow rings to seat properly. If the crosshatch is too steep, oil retention will be reduced. A crosshatch angle which is too shallow will cause ring vibration, poor sealing, and overheating of the rings due to blow-by and reduced contact with the cylinder wall. Service life of the pistons and rings will be greatly reduced.

* Except Nicasil

Cylinder Hone Selection

Selecting a hone which will straighten as well as remove material from the cylinder is very important. Honing a cylinder with a spring loaded glaze breaker is never advised. Polaris recommends using a rigid type hone which also has the capability of oversizing. These hones are manufactured by such companies as Sunnen Products Company of St. Louis, Missouri; and Ammco Tools, Inc., of North Chicago, Illinois.

De-glazing

If cylinder wear or damage is minimal, hone the cylinder lightly with finish stones following the procedure outlined on page 2.48

Honing To Oversize

If cylinder wear or damage is excessive, it will be necessary to oversize the cylinder using a new oversize piston and rings. This may be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by finish honing.

For oversize honing always wet hone using honing oil and a coarse roughing stone. Measure the piston (see piston measurement) andrough hone to the size of the piston or slightly larger. Always leave .002 - .003s (.05

- .07 mm) for finish honing. Refer to the Snowmobile

Service Manual for piston tocylinder specifications before honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance. See procedure on page 2.48.

EXAMPLE OF CROSS HATCH PATTERN

2.47

ENGINE

Honing Procedure

1. Wash cylinder with solvent. Clamp cylinder securely in a soft jawed vise by the exhaust port studs.

2. Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls (DO NOT OVERTIGHTEN). Cylinders may be wet or dry honed depending on the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore. Using a 1/2I (13 mm) drill motor rotating at a speed of 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 to prevent edge loading and always bring the stone approximately 1/2I (1.3 cm.) beyond the bore at the end of each stroke. Release the hone at regular intervals to inspect bore size and finish. Do not “drag” the hone out of the bore.

Honing Procedure - Nicasil

Ni-Ca-Sil cylinders can be lightly honed if the proper stone is used. Ammco #3955 honing stones (for use with the Ammco 3950 cylinder hone) are suitable and can be ordered through most automotive supply stores or VST. See General Information chapter for tool ordering information.

Port Chamfering

Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed. Make sure there are no sharp edges.

IMPORTANT:

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Premium 2 Cycle Lubricant.

Crankcase Inspection / Bearing Fit

Any time crankshaft bearing failure occurs and the case is to be reused, Polaris recommends checking the bearing fit into the case halves using the following procedure.

1. With case halves cleaned, press a replacement bearing into each of the main bearing journals to determine a basic amount of press fit. NOTE: Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if any are noticeably loose or tight. Normal hand installation will be an indication of the recommended interference fit. If the bearing falls out of the case when the case is inverted, the case should be replaced.

Crankcase Bearing Interference Fit:

C-3 - .0006s (.015mm) - Crush C-4 - .001s (.025mm) - Crush

Crankshaft Main Bearing Inspection

1. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 engine oil. Carefully check each main bearing on the shaft.

NOTE: Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly. The inner race of each bearing should fit tightly on the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement. Replace any loose or roughbearings.

2.48

Connecting Rod (Big End) Bearing Inspection

1. Measure connecting rod big endside clearance with a feeler gauge. Clearance should be equal on all rods (within .002s). Rotate rod on crankshaft and check for rough spots. Check radial end play in rod by supporting rod against one thrust washer and alternately applying up and down pressure. Replace bearing, pin, and thrust washers if side clearance is excessive or if there is any up anddown movement detectable in the big end bearing.

NOTE: Specialized equipment and a sound knowledge of crankshaft repair and straightening is required to perform crankshaft work safely and correctly. Crankshaft repair should be performed by trained Polaris service technicians in a properly equipped shop.

Piston Pin / Needle Bearing Inspection

ENGINE

1. Clean needle bearing in solvent and dry with compressed air.

2. Inspect needle cage carefully for cracks or shiny spots which indicate wear. Replace needle bearings if worn or cracked, and always replace them if piston damage has occurred.

3. Visually inspect piston pin for damage, discoloration, or wear. Run your fingernail along the length of the pin and replace it if any rough spots, galling or wear is detected.

Connecting Rod Small End Inspection

1. Clean small end of connecting rod and inspect inner bore with a magnifying glass. Look for any surface irregularities including pitting, wear, or dents.

2. Run your fingernail around the inside of the rod and check for rough spots, galling, or wear.

3. Oil and install needle bearing and pin in connecting rod. Rotate pin slowly and check for rough spots or any resistance to movement. Slide pin back and forth through bearing while rotating and check for rough spots.

4. With pin and bearing centered in rod, twist ends back and forth in all directions to check for excessive axial play. Pull up and down evenly on both ends of pin to

and

check for radial play. Replace pin is any resistance to rotation or excessive axial or radial movement. If play or roughness is evident with a new pin and bearing, replace the connecting rod.

bearing if there

2.49

ENGINE

Crankshaft Truing

Lubricate the bearings and clamp the crankshaft securely in the holding fixture. On three cylinder crankshafts, straighten one of the ends (Magneto or PTO) and then straighten the center section. Place the center section in the holding fixture and then straighten the remaining end. If truing the crankshaft requires striking with a hammer, always be sure to re-check previously straightened areas to verify truing. Refer to the illustrations below.

Crankshaft Alignment Fixture

PN 2870569

Crankshaft Runout Inspection

When checking the crankshaft runout, it is important to measure with a dial indicator in the correct position.

When measuring on the flywheel side: SMeasure runout 1/2” (12.7mm) from the bearing flat.

When measuring from the PTO side: SMeasure runout where the taper starts after the

bearing flat.

Refer to the illustrations. Acceptable crankshaft runout is .000--.004” (0--.10mm) for all Polaris crankshafts.

1/2” (12.7mm)

Flywheel (MAG) side

Measure where taper starts

PTO Side

2.50

Crankshaft Truing

NOTE: The rod pin position in relation to the dial indi-

cator position tells you what action is required to straighten the shaft.

ENGINE

5. To correct a situation like the one shown in the illustration at right, strike the shaft at point A with a brass hammer.

NOTE: The rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft.

6. To correct a situation like the one shown in the illustration at right, squeeze the crankshaft at point A. (Use tool from alignment kit).

7. If the crank rod pin location is 180_ from the dial indicator (opposite that shown above), it will be necessary to spread the crankshaft at the A position as shown in the illustration at right. When rebuilding and straightening a crankshaft, straightness is of utmost importance. Runout must be as close to zero as possible.

NOTE: Maximum allowable runout is .004I (.1 mm).

HIGH .004 (.1mm)

SUPPORT CRANKSHAFT AT THESE TWO BEARINGS

HIGH .002 (.05mm)

HIGH .004 (.1mm)

HIGH .005 (.13mm)

2.51

ENGINE

Crankshaft Indexing

Polaris crankshafts are pressed together or ‘‘indexed” so the connecting rod journal center lines are 180q (twins) or 120q (triples) apart from each other.

It is sometimes necessary to check multi-cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders. Causes for out-of-index crankshafts include but are not not limited to:

S Hydrolock from water or fuel; S Impact to drive clutch from foreign object or accident; S Abrupt piston or other mechanical failure; S Engine lock-up due to drive belt failure;

Following is a method of checking:

CAUTION:

Disconnect battery ground cable and all spark plug high tension leads; ground high tension leads to engine. Disconnect lanyard from engine stop switch before proceeding with the following steps.

1. Securely fasten a degree wheel on the flywheel or PTO end of crankshaft. Use a large degree wheel for more accuracy, and make sure it is mounted concentrically with the crankshaft center line.

2. Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot. Point the sharpened end at the outer perimeter of the degree wheel.

Dial Indicator

.100 ATDC

3. Install a dial indicator into the magneto end cylinder spark plug hole (front) (#1). (The ignition timing is referenced by the magneto end.)

4. Rotate the engine to bring the piston to top dead center (TDC) on the cylinder with the indicator installed.

5. Locate TDC as accurately as possible by finding the center of the point where there is no piston movement. ‘‘Zero” the dial indicator at this point. Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100s (2.54mm) after top dead center (ATDC). IMPORTANT: Do not allow the crankshaft to move from this position.

Degree Wheel

Crankshaft Indexing (Continued)

6. Bend the pointer or move the degree wheel until the pointer aligns with the 180q or 120q mark on the degree wheel.

7. With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position. Re-check accuracy of this location by repeating steps 4. and 5. . The pointer should align with the 180q or 120q mark when the dial indicator reads .100s (2.54mm) ATDC.

IMPORTANT:

read the wheel and dial indicator.

8. Remove the dial indicator and install in cylinder #2 or center cylinder. Repeat steps 4. and5. Note thedegree wheel indication when the dial indicator reads .100s ATDC. It should be 180q or 120q (r 2q) from cylinder #1. Repeat procedure on PTO cylinder (#3) where applicable. Cylinder #3 should also be120q¢r 2q) from cylinder #1.

Symptoms of an out of index crankshaft can include:

Do not

move the degree wheel or pointer after the initial setting on the mag end cylinder - simply

S Difficulty calibrating carburetor (repetitive plug fouling on one cylinder with no other cause); S Unexplained piston failure on one cylinder (i.e. severe detonation, broken ring lands, piston holing); S Excessive vibration of engine, backfiring, etc.; S Rough idle, poor top speed.

2.52

Exhaust Gas Temperature

ENGINE

Above 1200_F 649_C

1150 - 1200_F 621 - 649_C

Multiple Cylinder Single Pipe

NOTE: The temperatures given are approximate and should only be used as an example. You must determine the

EGT numbers that are correct for your machine

--DETONATION

--NORMAL

1.5” 38mm

Above 1200_F 649_C

1150 - 1200_F 621 - 649_C

5.0” 127mm

1PipePerCylinder

--DETONATION

--NORMAL

For more information contact Bill Rader (715) 355-5157

2.53

ENGINE

Piston Wash and Spark Plug color

Changing temperature, barometer, altitude, and fuel supply are just a few of the factors that can affect the day to day performance of your engine. That is why using Exhaust Gas Temperatures (EGTs) are important for maintaining optimum performance.

There are two methods for helping you determine what the EGTs are for your machine. Piston wash and the coloring of your spark plug.

The piston wash is by far the most valuable tool in concluding EGTs, with the spark plug color running a distant second. Use the illustrations below to help you establish the EGTs for your machine.

Piston Wash

n Wet and Black wash indicates too rich a

fuel mixture

Wash

Correct

n If the wash is 1/4” - 3/8” and cocoa

brown, the machine’s EGTs are just right.

Dry

n A dry, ash colored piston indicates too lean

a mixture for the operating conditions.

Spark Plug Color

n If the plug is wet or very dark, the fuel is

running too rich.

Correct

n If the plug is light to cocoa brown, the

machine’s EGTs are just right.

n A ash white plug with speckles indicates

too lean a mixture for the operating conditions.

Once the proper jetting is established, you can reference the EGT gauge for your baseline numbers. Then, if there is a rise or fall of 25 degrees, you must jet accordingly to return your EGTs to the baseline numbers.

2.54

Cylinder Head Inspection

1. Inspect each cylinder head for warping. Replace cylinder head if warp exceeds service limit.

Cylinder Head Warp

Service Limit: .003s (.08mm)

Cylinder Measurement

2. Inspect each cylinder for wear, scratches, or damage. If no damage is evident, measure the cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure the bore 1/2s from the top of the cylinder; in line with the piston pin and 90q to the pin to determine if the bore is out of round. Repeat the measurements at the middle and bottom of the cylinder to determine taper or out of round at the bottom. Record all measurements.

To p

ENGINE

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Middle

Bottom

2.55

ENGINE

Piston Inspection/Measurement

1. Check piston for scoring or cracks in piston crown or pin area. Excessive carbon buildup below the ring lands is an indication of piston, ring or cylinder wear.

2. Measure piston outside diameter at a point 10 mm (3/8s) up from the bottom of the skirt at a 90q angle to the direction of the piston pin (domestic engines). For Fuji engines, measure 1/2s (12.7mm) up from the bottom of the piston skirt. Record the measurement for each piston.

NOTE: The piston must be measured at this point to provide accurate piston-to-cylinder clearance measurement.

3. Subtract this measurement from the minimum cylinder measurement recorded previously. If clearance exceeds the service limit, the cylinder should be re-bored and new pistons and rings installed.

Piston Ring Installed Gap

90q to pin

FUJI ENGINES - Measure 1/2s (12.7mm) up from bottom of skirt

DOMESTIC ENGINES - Measure 3/8s (10.0mm) up from bottom of skirt

1. Position ring 1/2I (1.3 cm.) from the top of the cylinder using the piston to push it squarely into place. Measure installed gap with a feeler gauge at both the top and bottom of the cylinder.

NOTE: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round. Replace rings if the installed end gap exceeds the service limit.

NOTE: Always check piston ring installed gap after reboring a cylinder or when installing new rings.

Cylinder

1/2s (1.3cm.)

Piston Ring

Feeler Gauge

1/2s (1.3cm.)

Piston Ring

2.56

Straight Edge

Piston Ring Cutaway

Keystone Piston Ring

ENGINE

Oil Pump Operation and Troubleshooting

Any time the engine is disassembled or repaired, it is important that the oil supply from the pump to the engine be checked.

NOTE: Banjo type or pressed in valves should open with 2 to 7 lbs. of pressure. Perform this test with 40:1 premix in fuel tank.

1. With engine in chassis, oil reservoir full, and pump bled, remove two oil feed line banjo bolts (A) from their location on the manifold or carburetors. NOTE: Install new sealing washers upon installation on either side of the banjo check valve.

2. Loosely thread only the banjo bolts back into the manifold or carburetors.

3. Place oil feed lines with their check valves away from the clutch area. Start the engine and let it idle at normal idle RPM.

4. Lift oil pump control lever up to its maximum flow position.

5. Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes, with a drop occurring approximately every few seconds.

Pressed

Apply Pressure Here To Te st

Banjo

6. If oil does not flow from one of the check valves, remove oil line from check valve and again idle engine. If oil then flows, the check valve is defective and must be replaced.

7. If oil does not flow with check valves removed from their feed lines, the malfunction is one of the following:

S Inline filter blocked

S Air not bled from oil pump

S Feed lines leaking

S Oil tank vent restricted or kinked

S Defective pump.

2.57

ENGINE

Oil Pump Bleeding

The oil pump must always be bled following any service to the injector system or engine which allows the loss of oil and subsequent entrapped air during reassembly.

1. Fill oil reservoir with Polaris injector oil.

2. Loosen brass hex head screw (A). After a short time oil should flow from beneath the screw head to indicate the pump is free of air.

3. Tighten bleed bleed screw.

Oil Pump Adjustment - All Models

After the engine RPM and carburetor adjustments have been made, the oil pump must also be adjusted.

1. With engine shut off and throttle in its idle position, the pump lever index mark (A) must align with the pump housing boss index mark (B).

2. Loosen lock nuts on cable housing sleeve and vary cable housing length as required. NOTE: Verify that pump lever is actuated upon initial throttle opening.

Oil Pump Drive Gear End Play Adjustment

If the oil pump, crankcase, or any other oil pump drive component is replaced, inspect the drive gear end play using the following procedure:

1. Measure distance from oil pump mounting surfaceto bushing. Call this measurement “A”.

NOTE: Make sure the bushing is fully seated in the crankcase.

2.58

ENGINE

Oil Pump Drive Gear End Play Adjustment - Fuji

2. Measure distance from oil pump mounting flange surface to end of seal flange as shown. Call this measurement “B”.

3. Subtract measurement “B” from “A” to determine total bushing end play.

4. Measure thickness of existing shims and subtract from total bushing end play determined in step 3.

5. Add or subtract shims as required to provide specified end play.

6. Lightly grease a new O-ring and install it on the pump. Install pump, engaging slot in shaft with drive gear. Apply Loctite¥ 242 to bolts and torque evenly to 78 in. lbs. (9 Nm).

Measurement A

Oil Pump Mounting Bolt Torque (242 Blue)

78 in. lbs (9 Nm)

Optional Shims:

PN 3083671 = .006s(.15mm) PN 3083672 = .012s (.3mm) PN 3083673 = .024s (.6mm)

End Play

.008 - .016s (.203 - .406 mm)

Measurement B

2.59

ENGINE

WARNING

Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be removed, the engine must be cool. Severe personal injury could result from steam or hot liquid. Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement, install the correct Polaris cap with the same pressure rating. Refer to the appropriate parts manual.

NOTE: Always use Polaris premium antifreeze 60/40 premix. Bleed system at specified RPM or air will remain trapped in system, which may result in overheating.

Filling and Bleeding Procedure

If the cooling system should become low in the reservoir tank and/or filler neck, the system should be bled of any trapped air using one of the following procedures, depending on model.

440/500/600/700 Domestic Twins Bleeding Procedure

1. Fill cooling system . Leave pressure cap off.

2. With engine running at specified idle speed, loosen bleed screw on thermostat housing.

3. Continue adding antifreeze mixture to reservoir until system is purged of air.

4. Close bleed screw and tighten securely.

5. Fill reservoir bottle until coolant level is between the minimum and maximum fill marks.

6. Replace pressure cap.

7. Start engine and test for leaks.

500/600/700 Libertyt Twins

Bleed Screw

2.60

Cooling System - 440 Pro X

ENGINE

NOTE: When leak testing cooling system, system

pressure should not exceed 2 lbs. less than cap pressure.

ENGINE

CENTER

COOLER

440 Pro X

COOLANT BOTTLE

TUNNEL STRIP COOLERS

2.61

ENGINE

Cooling System 600 Pro X

ENGINE

CENTER

COOLER

600 Pro X

COOLANT BOTTLE

TUNNEL STRIP COOLERS

2.62

Cooling System 700 / 800 Pro X

ENGINE

CENTER

COOLER

700/800 PRO X

COOLANT BOTTLE

TUNNEL STRIP COOLERS

2.63

ENGINE

Troubleshooting

PROBLEM PROBABLE CAUSE

Will not start/ hard starting

Low compression

No spark -Spark plug fouled

Engine idles but no acceleration

Engine runs but fails to reach maximum RPM

Engine runs but fails to idle

Engine runs, but overloads with fuel

Carburetion and plug fouling

Engine runs but overheats

-Check ignition switch for run position, moisture contamination

-Check auxiliary shut-off switch operation

-Check fuel supply

-Check wiring from engine to coil(s) or spark plug(s)

-Check spark plug(s)

-Disconnect engine connector to eliminate any shorts that might be in the system

-If starter won’t work (electric models), check wires from starter solenoid and battery or check battery and battery cables

-Open or broken reed valves

-Crankcase plug is out

-Head gasket faulty

-Poor ring sealing, piston damage

-Secondary coil bad or wires disconnected

-Primary coil shorted or open

-Ignition switch shorted, contaminated with moisture

-Auxiliary switch shorted or contaminated with moisture

-Restricted fuel flow/air flow

-Clogged main jet

-Timing

-Clutching

-Clogged fuel filter

-Incorrect track tension

-Incorrect main jet

-Throttle slides not fully open

-Chain too tight

-Clutching

-Excessive driveline friction (Hi-Fax overheating)

-Incorrect air mixture setting

-Throttle stop screw incorrectly adjusted

-Dirt in pilot jet

-Low compression

-Tight belt

-Piston damage

-Chokes not seating

-Chokes are not seating

-Fuel pump diaphragm is ruptured (caused by engine backfiring)

-Carburetor slides are not synchronized

-Too large main jet

-Needle and seat not seating properly

-Incorrect float level

-Check reed valve condition

-If a lot of riding is on trails, and plugs foul and get black when doing so, verify carb sync, oil pump adjustment, pilot screw setting, spark plug type and gap, venting for carbs, proper jetting for altitude and temperature, belt tension, clutch operation. If tune up items are correct, check: float level, jet needle position, jet needle wear, inlet needle and seat wear, etc.

-Coolant level

-Incorrect main jet

-Incorrect timing

-Incorrect spark plug

-Water pump belt loose or broken

-Cooling restriction

-Air in cooling system

-Inadequate snow for cooling (ice and/or marginal conditions)

all

tune up adjustments:

2.64

Jet Part Numbers 3.1 -- 3.3..............................

Jet Needle Overview 3.4...........................

Mikuni TMX--34 Exploded View 3.5..................

Mikuni TM 38/40 Exploded View 3.6.................

Mikuni VM 34 SS Exploded View 3.7.................

Fuel Delivery System 3.8...........................

Carbueretion Operation 3.9 -- 3.14.........................

Component Effect vs. Throttle Opening 3.15...........

VM 34 SS Throttle Syncronization Proceedure 3.16.....

Mikuni TM 38/40 Service 3.17 -- 3.21........................

Mikuni TM 38/40 Throttle Syncronization 3.22 -- 3.23..........

Mikuni TMX Service 3.24 -- 3.26............................

Adjustments 3.27 -- 3.28...................................

Choke 3.29........................................

Fuel Pump 3.30....................................

Troubleshooting 3.31 -- 3.32................................

CARBURETION

Jet Part Numbers

Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

Jet Part Numbers

The following chart lists main and pilot jets and the part number of each that are presently available.

Mikuni Mikuni

PILOT JET NO. PART NO. PILOT JET NO. PART NO.

25 3130064 60 3130071............ ........

30 3130065............

35 3130066............

40 3130067............

45 3130068............

50 3130629............

55 3130070............

Mikuni Mikuni

HEX HEAD HEX HEAD MAIN JET NO. PA RT NO . MAIN JET NO. PART N O.

80 3130099 250 3130128 510N 3131400............ ............ ........

85 3130100 260 3130129 520N 3131401............ ............ ........

90 3130101 270 3130130 530N 3131402............ ............ ........

95 3130102 280 3130131 540N 3131408............ ............ ........

100 3130103 290 3130132 550N 3131409........... ............ ........

105 3130104 300 3130133 560N 3131410........... ............ ........

110 3130105 310 3130134........... ............

115 3130106 320 3130135 The “N” series jets have the same........... ............

120 3130107 330 3130136 flow characteristics as the following............ ............

125 3130108 340 3130137 510N = 540........... ............

130 3130109 350 3130138 520N = 580........... ............

135 3130110 360 3130139 530N = 600........... ............

140 3130111 370 3130290 540N = 620........... ............

145 3130112 380 3130140 550N = 660........... ............

150 3130113 390 3130480 560N = 700........... ............

155 3130114 400 3130141........... ............

160 3130115 410 3130599 Do NOT substitute a........... ............

165 3130116 420 3130142 530 Main Jet in place of a 530N ............ ............

170 3130117 430 3130143........... ............

175 3130118 440 3130144........... ............

180 3130119 450 3130145........... ............

185 3130120 460 3130146........... ............

190 3130121 470 3130147........... ............

195 3130122 490 3130148........... ............

200 3130123 500 3130149........... ............

210 3130124...........

220 3130125...........

230 3130126...........

240 3130127...........

3.1

CARBURETION

Mikuni TM-38/TM-40 Jet Part Numbers

DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER

Jet Needles Pilot Air Jets Cont.

Jet Needle J8-9FH04-57 3130794 Pilot Air Jet 1.0 3131257

Jet Needle J8-9EH01-57 3130795 Pilot Air Jet 1.1 3131258

Jet Needle J8-9DH01-54 3130796 Pilot Air Jet 1.2 3131259

Jet Needle J8-9CJB01-50 3130797 Pilot Air Jet 1.3 3131260

Jet Needle J8--8BEY01 3131250 Pilot Air Jet 1.4 3131261

Jet Needle J8--9DFH06--57 3131253 Pilot Air Jet 1.5 3131262

Jet Needle J8--9DFH07--60 3131268 Pilot Air Jet 1.6 3131263

Jet Needle J8--9DFH10--57 3131313 Pilot Air Jet 1.7 3131264

Jet Needle J8-- 9DGI01--60 3131377 Pilot Air Jet 1.8 3131265

Jet Needle J8--9DGJ02--57 3131378 Pilot Air Jet 1.9 3131266

Jet Needle J8-- EFH01--60 3131207 Pilot Air Jet 2.0 3131267

Jet Needle J8-- 9EFY02--61 3131202 Throttle Valves

Pilot Air Jets (Short) Piston Valve 1.5 3130940

Pilot Air Jet 0.5 3130773 Piston Valve 2.0 3130789

Pilot Air Jet 0.6 3130774 Piston Valve 2.5 3130790

Pilot Air Jet 0.7 3130775 Piston Valve 3.0 3130791

Pilot Air Jet 0.8 3130776 Piston Valve 3.5 3130792

Pilot Air Jet 0.9 3130777 Piston Valve 4.0 3130793

Pilot Air Jet 1.0 3130778

Pilot Air Jet 1.1 3130779

Pilot Air Jet 1.2 3130780

Pilot Air Jet 1.3 3130781

Pilot Air Jet 1.4 3130782

Pilot Air Jet 1.5 3130783

Pilot Air Jet 1.6 3130784

Pilot Air Jet 1.7 3130785

Pilot Air Jet 1.8 3130786

Pilot Air Jet 1.9 3130787 Starter Jets Part Number

Pilot Air Jet 2.0 3130788 Starter Jet 130 3130805

Pilot Air Jets (Long) Starter Jet 135 3130767

Pilot Air Jet 0.5 3131255 Starter Jet 140 3130768

Pilot Air Jet 0.6 3131249 Starter Jet 145 3130769

Pilot Air Jet 0.7 3131256 Starter Jet 150 3130770

Pilot Air Jet 0.8 3131254 Starter Jet 155 3130771

Pilot Air Jet 0.9 3131203 Starter Jet 160 3130772

The part numbers for main jets and pilot jets are the same as Mikuni VM round slide carburetors.

3.2

Polaris 2003 Pro X Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual