Page 2 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.
Page 3 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.
Page 4 As a part of the Polaris team, your input is highly valued and never ignored. 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.
Page 6 PRO X Introduction ........Initial Break--In .
Page 7: Pro X Introduction
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.
Page 8 Please install this Head Kit PN 2202188 on all 440 Pro X Liquid mod- els that will be used for trail riding. The installation of this kit must be performed by an authorized Polaris dealer. 2003 440 Pro X 92 Octane Jetting Chart...
Page 9: Publication Numbers
GENERAL INFORMATION Publication Numbers Owner’s Manual Parts Parts Model Model No. Supplement Manual Microfiche 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...
Page 10 GENERAL INFORMATION 440 PRO X Fan MODEL: ..MODEL NUMBER: S03NX4FS ENGINE MODEL: EC45PM040 JETTING CHART AMBIENT TEMPERATURE CARBURETION Below -30 F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F Altitude...
Page 11 Driveshaft Sprockets 2 Drivers Front Vertical Travel 9.22 (23.4 cm..) Brake Type ..Polaris HPB Rear Suspension . . . Pro X Rear Travel ..
Page 12 GENERAL INFORMATION 440 PRO X MODEL: ..MODEL NUMBER: S03NX4CS ENGINE MODEL: S2424- -4460PA4C JETTING CHART FOR 110 OCTANE AMBIENT TEMPERATURE Below -30 F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F...
Page 13 GENERAL INFORMATION 440 PRO X MODEL: ..MODEL NUMBER: S03NX4CS ENGINE MODEL: S2424- -4460PA4C ELECTRICAL CAPACITIES Flywheel I.D..4010629 Fuel Tank ..5 Gal.
Page 14 GENERAL INFORMATION 600 PRO X MODEL: ..MODEL NUMBER: S03NX6ES ENGINE MODEL: S2392- -6044PA6E JETTING CHART CARBURETION Type ....TM 38 Mikuni w/TPS AMBIENT TEMPERATURE Main Jet...
Page 15 Front Spring Preload 2.75 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9.22 (23.4cm..) Brake Type ..Polaris HPB, Liquid Cooled Rear Suspension . . . PRO Xt Rear Axle Travel . . .
Page 16 GENERAL INFORMATION 700 PRO X MODEL: ..MODEL NUMBER: S03NX7CS ENGINE MODEL: S2378- -7070PA7C JETTING CHART AMBIENT TEMPERATURE CARBURETION Below -30 F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F Altitude...
Page 17 Front Spring Preload 2.75 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9.22 (23.4cm..) Brake Type ..Polaris HPB, Liquid Cooled Rear Suspension . . . PRO Xt Rear Axle Travel . . .
Page 18 GENERAL INFORMATION 800 PRO X MODEL: ..MODEL NUMBER: S03NX8CS ENGINE MODEL: S2398- -8070PA8C JETTING CHART AMBIENT TEMPERATURE Below -30 F -30_ to - -10_F - -10_to +10_F +10_to +30_F +30_to +50_F Above +50_F Altitude ltitude...
Page 19 Front Spring Preload 2.75 Thread Adjust Driveshaft Sprockets 2 Drivers Wide Front Vertical Travel 9.22 (23.4cm..) Brake Type ..Polaris HPB, Liquid Cooled Rear Suspension . . . PRO Xt Rear Axle Travel . . .
Page 20 GENERAL INFORMATION Bolt Size Threads/In Grade 2 Grade 5 Grade 8 (MM/Thread) Torque in. lbs. (Nm) ....27 (3.1) ....43 (5.0) .
Page 21: Table Of Contents
GENERAL INFORMATION 1/64 ......0156 1/32 ..... .0312 .
Page 22: Table Of Contents
GENERAL INFORMATION Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.382 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs. kg-m x 7.233 = ft.
Page 23 GENERAL INFORMATION SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48 7/8-9 49/64...
Page 24 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.
Page 25 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.
Page 26 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.
Page 27 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.
Page 28: Tool List
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 TEAM Clutch Compression Tool Extensions (To be used with Clutch Com- PS--45909 pression tool) 2870576 Drive Clutch Bore Tapered Reamer 2870910 Roller Pin Tool...
Page 29: Recommended Maintenance Products
GENERAL INFORMATION Recommended Maintenance Products ENGINE OIL RETAINING/SEALING PRODUCTS Packaging Packaging Part # Description Part # Description (size / quantity) (size/quantity) 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...
Page 31 Improvements and Specifications ....Torque Specifications ......Spark Plugs .
Page 33 ENGINE Improvements for 2003 440 Pro X 1. V--Forcet Reeds 2. Revised carburetion calibration 3. “Dragon” ignition system V FORCEt REEDS Pro X Model Specifications Machine Model Engine Model Cyl. Bore Bore Stroke Stroke No. of Type of Fuel Disp. Inches Inches Cyl.
Page 34 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) Spark Plugs Polaris Part Spark Plug Number 3070156 NGK BR8ES 3070157 NGK BR7ES...
Page 35 ENGINE CYLINDER BASE CYLINDER HEAD 440/600 Pro X 440/600 Pro X CRANKCASE - 440/600 Pro X CRANKCASE - Pro X CYLINDER HEAD - Pro X Fan CYLINDER HEAD Libertyt 700 / 800 CYLINDER BASE Libertyt 700/800 Libertyt Crankcase - 700 / 800...
Page 36 ENGINE IHV = INSTALLED HEAD VOLUME [CC] R = (IHV+DISP) DISP= CYLINDER DISPLACEMENT [CC] = COMPRESSION RATIO = FULL ENGINE STROKE [CM] (DISP*25.4) = INCHES PER CC OF IHV = CYLINDER BORE [CM] DISP = (PI*B*B*S) = 3.1416 Bore = 6.5 cm. Stroke = 6.0 cm.
Page 37 ENGINE 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 Stroke Number of inches to remove from the cylinder head to equal 1 cc Displacement 2.54 I = 0.01186...
Page 38 ENGINE Variable Exhaust System (V.E.S.) Some snowmobiles are equipped with the Polaris Variable Exhaust System (V.E.S.) This unique exhaust valve management system changes the effective exhaust port height in the cylinder to pro- vide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange throttle settings.
Page 39 Valve cover miles, depending on operating conditions. To ensure maxi- Spring mum performance and minimize required maintenance, Polaris recommends the use of Polaris Synthetic 2 Cycle Valve cap Bolt lubricant only. The use of other lubricants may cause im- Bellows...
Page 40 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.
Page 41 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 is located on the airbox and has seven optional curves. These seven options are used to match the fuel type and the racing conditions which may vary, depending on the race.
Page 42 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.
Page 43 ENGINE Disassembly - Continued 4. Remove the carburetor mounting boots using a allen wrench. 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.
Page 44 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.
Page 45 ENGINE Disassembly - Continued 10. Remove the recoil cam. 11. Loosen and remove the flywheel nut. 12. Using a flywheel puller, remove the flywheel from the engine. Do not install puller bolts more than 5/16 (7mm) into flywheel threads or stator damage may result. Flywheel Puller PN 2871043 2.13...
Page 46 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...
Page 47 ENGINE 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”. 18. Loosen and remove each cylinder. 2.15...
Page 48 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.
Page 49 ENGINE 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. 2. Insert oil pump drive gear. 3.
Page 50 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.
Page 51 ENGINE 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.
Page 52 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.
Page 53 ENGINE 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. Flywheel Holding Wrench- PN 8700229 Flywheel Nut Torque 60 - 65 ft.lbs.
Page 54 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.
Page 55 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, Reed Pedal Exaggerated stuffers, and oil pump.
Page 56 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.
Page 57 ENGINE 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 T-Handle PN 5020326 11. Before removing stator plate, note where ignition timing marks are located, or scribe additional marks for reference upon reassembly.
Page 58 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.
Page 59 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. Lubricate shaft, insert shaft through the case on water pump side into the bushing on oil pump side.
Page 60 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.
Page 61 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.
Page 62 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.
Page 63 ENGINE 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.
Page 64 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.
Page 65 Libertyt 700 / 800 Engines NOTE: Inspect all parts for wear or damage during disassembly. It is recommended to re- place all seals, O-rings, and gaskets with Genuine Polaris parts during assembly. Refer to General inspection procedures in this chapter.
Page 66 ENGINE Disassembly, Cont. Flywheel Puller: PN 2871043 5. Remove flywheel using flywheel puller. 6. Note the ignition timing strip on the flywheel. Timing strip 7. Before removing stator plate, mark the plate and crankcase for reference upon assembly. Hose Clamp 8.
Page 67 ENGINE Disassembly, Cont. 9. Inspect water pump weep hole for signs of leakage or blockage. Inspect Weephole 10. Remove crankshaft seal from housing by driving seal to inside of housing. Replace seal if removed. 11. Remove water pump cover bolts and then remove impeller nut.
Page 68 ENGINE Disassembly, Cont. 13. Remove reed cover, reed stuffers, and reeds. Reed Valve Inspection Max Reed Pedal Exaggerated Clearance .015 for illustration 14. Measure air gap between fiber reed and reed (.38 mm). block as shown. The air gap should not exceed .015 (.4 mm).
Page 69 ENGINE 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 20. Remove water manifold by removing both retainer brackets. Remove Clamps 21.
Page 70 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.
Page 71 7. Install new O-rings on water manifold. Grease O-rings and install manifold. Replace O-rings 8. Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly. Gap Up 9.
Page 72 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.
Page 73 ENGINE Assembly, Cont. 16. Torque head bolts in proper sequence. Refer to specifications in the beginning of this chapter. 17. Reassemble water pump carefully installing seal. 18. Install crankcase seal to ignition/water pump housing from inside toward outside until bottomed on housing.
Page 74 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.
Page 75 ENGINE 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.
Page 76 4. Carbon deposits can be removed from valve with a Scotch Britet 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 bind- ing.
Page 77 ENGINE V.E.S. Assembly V.E.S. Assembly 1. Insert exhaust valve into valve housing. Re- place housing gasket. 2. Install washer, beveled side out, and bellows. 3. Apply Loctitet 262 to the threads of valve and install valve cap. Torque to specification. Valve Cap Torque: 6 Ft lbs (8.3 Nm) 4.
Page 78 ENGINE Polaris Variable Exhaust System Springs LOAD @ 1.0 In LOAD @ .630 in FREE LENGTH WIRE DIA. PART NUMBER COLOR (LBS.) (LBS.) (REF)(IN.) (IN.) 7041786--01 RED/WHITE 1.854 .041 7041786--02 BLUE/WHITE 1.740 .045 7041786--03 GREEN/WHITE 1.930 .045 7041786--04 YELLOW/WHITE 1.620 .045...
Page 79 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.
Page 80 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 bear- ing fit into the case halves using the following procedure.
Page 81 NOTE: Specialized equipment and a sound knowledge of crankshaft repair and straightening is required to per- form 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 1.
Page 82 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. Measure where taper starts PTO Side...
Page 83 ENGINE 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. 5. To correct a situation like the one shown in the HIGH .004 (.1mm) illustration at right, strike the shaft at point A with a HIGH .004 (.1mm) brass hammer.
Page 84 ENGINE Crankshaft Indexing Polaris crankshafts are pressed together or ‘‘indexed” so the connecting rod journal center lines are 180 (twins) or 120 (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.
Page 85 ENGINE Exhaust Gas Temperature Exhaust Gas Temperature Above 1200_F --DETONATION Above 1200_F 649_C --DETONATION 649_C 1150 - 1200_F --NORMAL 1150 - 1200_F 621 - 649_C --NORMAL 621 - 649_C 1.5” 38mm 5.0” 127mm Multiple Cylinder Single Pipe 1 Pipe Per Cylinder NOTE: The temperatures given are approximate and should only be used as an example.
Page 86 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 maintain- ing optimum performance.
Page 87 ENGINE Cylinder Head Inspection 1. Inspect each cylinder head for warping. Replace cylinder head if warp exceeds service limit. Cylinder Head Warp Service Limit: .003 (.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.
Page 88 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 (3/8 ) up from the bottom of the skirt at a 90 angle to the direction of the piston pin (domestic engines).
Page 89 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.
Page 90 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.
Page 91 ENGINE Oil Pump Drive Gear End Play Adjustment - Fuji Measurement A 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.
Page 92 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.
Page 93 ENGINE Cooling System - 440 Pro X 440 Pro X ENGINE COOLANT BOTTLE CENTER COOLER NOTE: When leak testing cooling system, system TUNNEL STRIP COOLERS pressure should not exceed 2 lbs. less than cap pres- sure. 2.61...
Page 94 ENGINE Cooling System 600 Pro X 600 Pro X ENGINE COOLANT BOTTLE CENTER COOLER TUNNEL STRIP COOLERS 2.62...
Page 95 ENGINE Cooling System 700 / 800 Pro X 700/800 PRO X ENGINE COOLANT BOTTLE CENTER COOLER TUNNEL STRIP COOLERS 2.63...
Page 96: Troubleshooting
ENGINE Troubleshooting PROBLEM PROBABLE CAUSE Will not start/ -Check ignition switch for run position, moisture contamination hard starting -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...
Page 97 Jet Part Numbers ......3.1 -- 3.3 Jet Needle Overview ......Mikuni TMX--34 Exploded View .
Page 99 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.
Page 100 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 3131257 Jet Needle J8-9EH01-57 3130795 Pilot Air Jet 3131258 Jet Needle J8-9DH01-54 3130796 Pilot Air Jet 3131259 Jet Needle J8-9CJB01-50 3130797...
Page 101 CARBURETION Jet Part Numbers Jet Needle Part Numbers (Mikuni TMX- - 34) JET NEEDLE NO. PART NO. J8-6GL62 ..... . 3131107 J8-6GL63 .
Page 102 CARBURETION Mikuni TM 38 / TM 40 Jet Needle Overview This needle (example) is a 9DH01--57. The first number is Leaner the approximate overall length in 10mm increments of the jet needle. The 9 indicated the needle is approximately 90mm but less that 100mm in length.
Page 103 CARBURETION Exploded View - Mikuni TMX-34 Mixing Chamber Top (Incl. Gasket) Holder Guide Spring Plunger Spring Throttle Stop Screw Holder Guide Air Screw Ring Float E-ring Holder Jet Needle Washer Piston Valve Needle & Seat Main Jet Pilot Jet...
Page 104 CARBURETION Exploded View -Mikuni TM-38/TM-40 Top Cap Gasket Adjustment Screw Check Valve Ring Lever Plate Plate O-ring Packing Adjuster Funnel E-Ring Ring Spring Spring Guide Pilot Jet Holder Main Jet Piston Valve Starter Jet Spring Jet Needle Float/Needle & Seat Asm. Plunger Pilot Air Jet Float Body...
Page 105 CARBURETION Exploded View - VM34SS Mixing Chamber Top (Including Gasket) Throttle Spring Plunger Cap Throttle Plate Plunger Spring E-Ring Jet Needle Plunger Throttle Valve Needle Jet Spring Air Screw Plate Spring Float Arm Packing Throttle Stop Screw Pilot Float Pin Ring Main Jet Needle &...
Page 106 CARBURETION Fuel Delivery System - Typical The fuel system contains many components which directly affect fuel mixture and driveability. When performing diagnosis or carburetor maintenance, the entire fuel delivery system should be inspected. The illustration below shows parts of the system requiring periodic maintenance to ensure there is no fuel or air leaks present. Fuel filters should be replaced at least once per season.
Page 107 CARBURETION Typical Mikuni Starter System - Closed Throttle Mikuni carburetors use a starter enricher system rather than a choke. In this type of carburetor, fuel and air for starting the engine are metered with entirely independent jets. The fuel metered in the starter jet is mixed with air and is broken into tiny particles in the emulsion tube.
Page 108 CARBURETION Pilot System (0-3/8 Throttle) The pilot system’s main function is to meter fuel at idle and low speed driving. Though its main function is to supply fuel at low speed, it does feed fuel continuously throughout the entire operating range. Fuel for the pilot jet is drawn from the float bowl, mixed with air regulated by the air screw, and delivered to the engine through the pilot outlet.
Page 109 CARBURETION Slide Cutaway (1/8-3/8 Throttle) Throttle valve cutaway effect is most noticeable at 1/4 throttle opening. The amount of cutaway is pre-determined for a given engine to maintain a 14:1 air/fuel ratio at part throttle. A steep angle would indicate a fairly lean mixture because there is less resistance to air flow.
Page 110 CARBURETION Jet Needle/Needle Jet (3/8-3/4 Throttle) The jet needle and needle jet have the most effect be- tween 3/8 and 3/4 throttle opening. Some mixture adjust- ment can be accomplished by changing the location of the “E” clip on the needle. Moving the clip down raises the Clip Position needle in the jet passage and richens the mixture.
Page 111 Carburetors on most Polaris models are calibrated for an altitude of 0-3000 ft (0-900 meters) and ambient temper- atures between -20 to +10 F (-29 to -12 C). All carburetors must be re-calibrated if operated outside the pro- duction temperature and/or altitude range.
Page 112 CARBURETION Function The function of a carburetor is to produce a com- bustible air/fuel mixture by breaking fuel into tiny particles in the form of vapor, to mix the fuel with air in a proper ratio, and to deliver the mixture to the engine.
Page 113 CARBURETION Component Effect vs Throttle Opening EFFECT THROTTLE OPENING - TYPICAL MIKUNI Throttle Valve Cut-Away Jet Needle/Needle Jet Polaris TM-38/TM-40 Mikuni component effect versus throttle opening chart. needle valve main jet Main jet needle needle jet throttle valve bypass pilot outlet...
Page 114 CARBURETION Throttle Synchronization Procedure 1. Remove air box, noting position of throttle cable junction block. Reposition throttle cable and junction block in same position when air box is reinstalled. MIKUNI Throttle Cable Synchronization (Throttle Gap) Center of slide under cutaway 2.
Page 115 CARBURETION Mikuni TM-38 / TM-40 Carburetor Service CAUTION: Wear eye protection when using compressed air or cleaning solvents. Review all fuel system warnings found on page 3.1 before proceeding. Carburetor Removal, Disassembly, and Inspection 1. Remove carburetor rack from engine. Before disassembling, clean outside of carburetor thoroughly with solvent.
Page 116 CARBURETION Mikuni TM-38 / TM-40 Carburetor Service Disassembly Cont. 6. From top of carb, loosen allen head screw holding needle in position. Slide holding plate to side. 7. Reach into top of carb with a long nose pliers and pull out needle.
Page 117 CARBURETION Mikuni TM-38 / TM-40 Carburetor Service Carburetor Disassembly Cont. 10. Remove water trap/drain plug (17 mm) and single screw on bottom of carb. 11. Remove float body NOTE: Float body will not come off unless water trap/drain plug, which is threaded and screws into main jet housing, is removed.
Page 118 CARBURETION Mikuni TM-38 / TM-40 Carburetor Service Carburetor Disassembly 1. Remove main jet, starter jet, pilot jet, and idle screw. 2. Clean all passages in carburetor body with carburetor cleaner. Dry all passages and jets with compressed air. Replace gaskets and any parts which show wear or damage.
Page 119 CARBURETION Mikuni TM-38 / TM-40 Carburetor Service 3. Place carburetor in an inverted position. 4. Connect pressure tester to fuel inlet fitting. Apply 5 psi pressure and observe for one minute. The needle and seat should hold pressure indefinitely. If the pressure drops, carefully inspect the needle and the needle seat.
Page 120 CARBURETION Adjustments Throttle Synchronization Procedure- Mikuni TM-38 / TM-40Flatslide Carburetors Mikuni TM-38 / TM-40 carburetors are synchronized at wide open throttle without the engine running. The middle carburetor on triples, and the PTO side carburetor on twins have a non-adjustable set screw on the throttle shaft.
Page 121 CARBURETION Adjustments Throttle Synchronization Procedure- Mikuni TM-38 / TM-40 Flatslide Carburetors 5. On remaining carb(s), loosen phillips head screw inside the offset nut. 6. When screw is loose, hold throttle to wide open. Turn offset nut until throttle slide is in same position as base carburetor.
Page 122 CARBURETION Mikuni TMX Carburetor Service CAUTION: Wear eye protection when using compressed air or cleaning solvents. Review all fuel system warnings found on page 3.1 before proceeding. Carburetor Removal, Disassembly, and Inspection (Typical VM Mikuni) 1. Remove carburetor from engine. Before disassembling, clean outside of carburetor thoroughly with solvent.
Page 123 CARBURETION Mikuni TMX Carburetor Service Carburetor Disassembly and Inspection 1. Remove water trap assembly from float bowl and inspect O-ring, hose and clamp condition. Refer to exploded view corresponding with carburetor being serviced. 2. Inspect enricher (choke) fuel supply passage in bowl for obstruction.
Page 124 CARBURETION Mikuni TMX Carburetor Adjustments Float Level Adjustment 1. Remove float bowl. 2. With carburetor positioned as shown, float arm should be parallel with body Arms must be parallel to each other. 3. To adjust float arm, bend tang contacting inlet needle. CAUTION: Never bend the float arm itself.
Page 125 CARBURETION Adjustments Chart A The amount of air drawn into the cylinders is in- fluenced by such factors as altitude, temperature, humidity, etc. Suppose the amount of air drawn into the cylinders at an elevation of zero is taken as 100 (the temperature and humidity in this case are con- sidered constant).
Page 126 CARBURETION Adjustments - Jet Needle and Float Level Fine Tuning the Mikuni Carburetor A carburetor with a piston type throttle valve is also called a variable venturi type carburetor. In this type of carburetor, the needle jet and jet needle serve to control a proper air/ fuel mixture ratio at the medium throttle valve opening (be- tween 1/4 and 3/4 opening).
Page 127 CARBURETION Adjustments - Choke With the dash mounted choke control toggle flipped to the Choke Toggle Position full off position, the choke plunger must be seated on the fuel passage way in the carburetor. If the plunger is not seated on the passage way, the engine will flood or run too rich, causing plug fouling and very poor engine perfor- mance.
Page 128 CARBURETION Fuel Pump - Operation The fuel pumps on all Polaris engines are basically the same. The differences are in the size and location of the pumps. Pumps may be mounted on the crankcase or on the machine by using an impulse hose.
Page 129 CARBURETION Troubleshooting Fuel system diagnosis should follow a specific path, first examining the fuel tank, then the filters, fuel lines, vent lines, fuel pump, impulse hose, air box, exhaust system and finally the carburetors. The following troubleshooting information assumes that the general mechanical condition of the engine (pistons, rings, bearings, etc.) is good.
Page 130 CARBURETION Troubleshooting Troubleshooting Tips, 1/4-3/8 Throttle: Obstruction in main jet or needle jet Jet needle worn or out of adjustment Pilot system malfunction Incorrect throttle valve cutaway Troubleshooting Tips, 3/8-3/4 Throttle: Main jet incorrect size or clogged (lean) Needle jet setter O-ring damaged or loose Needle jet/jet needle worn (rich) Troubleshooting Tips, Full Throttle: Main jet size (rich or lean)
Page 131 ....... Driven Springs (Polaris Clutch) ......
Page 133 Essential Drive Clutch Tools Refer to the Service Tool Catalog (PN 9914681) for photos and descriptions of all tools. A tool catalog update is available through the Polaris parts department. The part number is 9915235. Description Part Number Offset Alignment Tool - 5/8”...
Page 134 CLUTCHING Drive Clutch Weight Identification - Actual Size G - (B Modified) Gram Weight: 34 1 Gram Weight: 37.5 1 Gram Weight: 41.5 1 Gram Weight: 47.5 1 PN 5630107 PN 5630109 PN 5630063 PN 5630080 Gram Weight: 49 1 Gram Weight: 32.5 1 Gram Weight: 51 Gram Weight: 53 1...
Page 135 CLUTCHING Drive Clutch Weight Identification - Actual Size Gram Weight: 44 1 Gram Weight: 53.5 1 Gram Weight: 52 1 Gram Weight: 50 1 PN 5630065 PN 5630234 PN 5630243 PN 5630244 10 Bushed 10M-W Bushed Gram Weight: 47.5 1 Gram Weight: 55.5 1 Gram Weight: 51.5 1 Gram Weight: 46 1...
Page 136 CLUTCHING Drive Clutch Weight Identification - Actual Size 10-62 Bushed 10-AL Bushed 10-66 Bushed 10-64 Bushed Gram Weight: 62 Gram Weight: 53 1 Gram Weight: 66 Gram Weight: 64 PN 1321586 PN 1321531 PN 1321584 PN 1321585 10-60 Bushed 10-58 Bushed 10A Bushed 10-56 Bushed Gram Weight: 60...
Page 137 CLUTCHING Drive Clutch Weight Identification - Actual Size S43H S47H S45H Gram Weight:43 1 Gram Weight:47 1 Gram Weight:45 1 PN 1321849 PN 1321850 PN 1321851...
Page 138 CLUTCHING Drive Clutch Spring Rate Chart 7042083 Black/Green Almond/ Almond Black 7041816 7041988 Drive Clutch Spring Compression Rate Chart Black/White 7041818 P-90 TRAVEL Almond/Blue P-85 TRAVEL 7041922 Dark Blue/White 7041781 Blue/Blue-Gold 7041080 Silver/Gold 7041286 Almond/Gold 7041645 Gold 7041148 Silver 7041062 7041083 2.25 2.00...
Page 139 CLUTCHING Drive Clutch Spring Data PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH +/- Force lbs. @ .125 2.50”- -1.19 (+/- - 12lbs.) 7041021 Clear .157 4.38 70--130 7041022 Black .140 4.25 44--77 7041063 Purple .168 4.37 75--135 7041062 Silver .208 3.12 75--243...
Page 140 CLUTCHING Driven Clutch Springs (Polaris Clutch) Part Number Description Soft 7041198 7041782 Black-5 Coil 7041501 Gold-6 Coil 7041296 Blue 7041499 Silver 7041646 Silver/Blue Firm 7042022 Blue/Orange Driven Spring Charts Blue/Orange Blue and Blue/Orange Silver/Blue Silver or Blue Silver/Blue Silver Gold and Black...
Page 141 CLUTCHING Effects of Driven Clutch Spring Increases in driven clutch spring preload will raise engine speed before the clutch starts shifting, allowing the clutch to backshift more quickly. Decreases in driven clutch spring preload will result in faster upshift, but will also slow backshift, thereby lowering engine RPM.
Page 142 CLUTCHING Effects of Driven Clutch Helix Ramp A larger helix angle will allow the clutch to upshift at a lower engine RPM. Less side force will be exerted on the moveable sheave and the clutch will upshift more rapidly. During backshift, a lesser helix angle will backshift more easily and keep engine RPM higher.
Page 143 On most models the production helix spring hole location is No. 2. Tension the spring 1/3 turn. Install helix key, thrust washer and snap ring. Polaris has several helix angles available for the driven clutch. Refer to the chart below for specific angle effects and identification. See NOTE: below.
Page 144 CLUTCHING TEAM CLUTCH INFO Driven Ramp RAMP PART NUMBER DESCRIPTION 66/44--.46 5133321 70/48--.36 74/48--.46 5133491 70/48--.46 74/48--.46 5133492 74/40--.46 72/44--.46 5133493 72/40--.46 70/44--.46 5133494 70/40--.46 68/44--.46 5133495 68/40--.46 66/48--.46 5133496 66/40--.46 64/44--.46 5133497 64/40--.46 62/44--.46 5133498 62/40--.46 58/44--.46 5133499 58/40--.46 5133687 58/44--.46 ER 66/44--.46...
Page 145 CLUTCHING High Performance Roller Helix explained The Helix for the High Performance Roller is designated for the angle and length of the angle on the back side of the helix. You will see that the first number designates the steepest angle. The second number designates the lowest angle, and the last number is a measurement of the length of the steepest angle.
Page 146 CLUTCHING P-85 Drive Clutch Exploded View - Typical Do not lubricate drive clutch components Cover Cover Bushing Retaining Ring Washer Spring Roller Jam Nut Weight w/Bushing Weight Pin Roller Pin Guide Button Shim Sleeve Bushing Moveable Insert Spider Spacer Clutch Assembly (Less weights, spring) Moveable Sheave Fixed Sheave...
Page 147 CLUTCHING P-85 Driven Clutch Exploded View - Typical Do not lubricate driven clutch components except inside of ramp helix hub to reduce fretting and corrosion. Stationary Sheave Driven Cap Ramp Driven Plate Driven Bushing Retaining Ring Adjustment Cam Spring Washer Washer Button Screw...
Page 148 CLUTCHING Team Roller Clutch Exploded View Windage Plate Driven Ramp Roller Spring Thrust Washer Moveable Sheave Spacer Stationary Sheave Windage Plate Clutch Assembly Replacement driven clutches come with out ramp. The moveable and stationary sheaves cannot be ordered as separate service parts. 4.16...
Page 149 CLUTCHING Operation The Polaris drive system is a centrifugally actuated variable speed belt drive unit. The drive clutch, driven clutch, and belt make up the torque converter system. Each clutch comes from the factory with the proper internal components installed for its specific engine model. Therefore, modifications or variations of components at random are never recommended.
Page 150 CLUTCHING Operation 9000 8000 ENGINE OPERATING RANGE 200 RPM 7000 6000 5000 ENGAGEMENT 4000 3000 If the weights are too heavy, or spring rate too low, the engine RPM will be low and the drive clutch will upshift too fast, keeping the engine out of its power band. 9000 8000 7000...
Page 151 CLUTCHING MAINTENANCE The driven clutch operates in conjunction with the drive clutch. Its function is to maintain drive belt tension pre- venting slippage, and sense variations in load requirements necessary to maintain optimum engine torque output and load requirements from the track. Output torque is transmitted through the chaincase jackshaft and chain- case to the front drive shaft and track.
Page 152 CLUTCHING Spider Indexing NOTE: Spider indexing affects clutch balance and belt to sheave clearance. Read procedures carefully before proceeding. 1. Before disassembling drive clutch, mark spider, cover, moveable sheave, and stationary sheave in line with a permanent marker as shown. 2.
Page 153 CLUTCHING Removal 1. Hold clutch with strap wrench. Remove drive clutch retaining bolt, grease puller thread and tip lightly and install puller into clutch. Tighten puller with a wrench, or strike t-bar with a hammer until clutch is removed. Strap Wrench PN 2870336 Clutch Puller PN 2872085 - 3/4-16x14mm Clutch Puller XCF: 2872084 2.
Page 154 CLUTCHING Disassembly and Inspection 1. Install drive clutch in clutch compression tool (8700220). Mark both moveable and fixed sheave, cover, and spider with a permanent marker. CAUTION: Sheaves must be marked to provide a reference point for clutch balance and spider indexing. If the sheaves are not marked, and spider shim washers are changed or misplaced, the clutch will be out of balance and must be replaced.
Page 155 CLUTCHING Disassembly, Cont. 5. Measure the total thickness of the spacer washers installed beneath spider and record. CAUTION: NOTE: In order to maintain proper belt-to-sheave clear- ance and clutch balance, the same washers (or equiva- lent total thickness) must be reinstalled during assembly. If sheaves are not marked, or if total thickness of existing shim washers under spider is not recorded, clutch will be out of balance when reassembled and must be replaced.
Page 156 CLUTCHING Spider Roller Removal 1. Remove spider buttons using button removal tool. Remove shims (if any are installed) and note location. NOTE:The drive clutch spider buttons for the 800 twin cylinder domestic engines are less exposed than typical. It will not be possible to remove the buttons with the traditional spider button removal tool.
Page 157 CLUTCHING Roller Installation, Cont. 3. Place roller on pin as it protrudes from first land. 4. Place a second washer on other side of roller. 5. Install service tool. 6. Place spider on a vise anvil and drive roller pin through to second land of spider.
Page 158 CLUTCHING Spider Button Shimming, Cont. Measure tower 2. Measure the dimension between towers at the lower width at bottom half of the towers as shown. of travel Use Dial Caliper 3. Install spider buttons using a soft face hammer. Measure each 4.
Page 159 CLUTCHING Drive Clutch Assembly 1. Place the correct number of spacer washers beneath the spider. Spacer PN 5132542 is a stepped washer that can be placed in addition to one of the above shims for precise shimming. 2. Assemble clutch making sure “X” marks on movable sheave and spider, or reference marks made before Marks disassembly are aligned to achieve proper balance.
Page 160 CLUTCHING Assembly, Cont. 5. Install spring and cover. Torque cover bolts evenly to specification. CAUTION:Carefully align bushing with shaft during installation of cover to prevent bushing damage. Maintain alignment by tightening cover bolts evenly and carefully. Spider Cover Bolt Torque - 90 in.
Page 161 CLUTCHING Installation, Cont. 4. Slide clutch fully onto crankshaft taper. 5. Install retaining bolt with any spacers, washers or O-rings. See appropriate parts manual for type and placement of retaining bolt components. 6. Torque retaining bolt to specifications. Hold clutch with strap wrench.
Page 162 CLUTCHING Driven Clutch Removal 1. Remove driven clutch retaining bolt. 2. Slide driven clutch off jackshaft. It may be necessary to use a puller on some driven clutches. P-85 clutches (externally adjustable) can be removed using a 3-point flywheel or steering wheel puller and the 1/4-20 adjustment bolt holes.
Page 163 CLUTCHING Disassembly 1. Place clutch on bench. CAUTION:Wear eye protection during disassembly and assembly of driven clutch. Clutch Compression Tool PN 8700220 2. Hold fixed sheave and turn movable sheave 1/4 turn. Hold movable in place tap helix down with a soft faced hammer.
Page 164 CLUTCHING Disassembly, Cont. 5. Remove driven clutch spring. Both spring tabs should line up. If not spring is fatigued and should be replaced. Tabs Aligned 6. Slide moveable sheave off and inspect sheave surfaces for wear or grooving. Note size and number of shim washers between sheaves.
Page 165 CLUTCHING Assembly 1. Install appropriate washer(s) on fixed shaft. Optional Thin Adjustment Washer (P-85) .048 - PN 7555899 2. Slide moveable sheave on fixed shaft. 3. Install driven clutch spring. Be sure spring tab is seated in hole in moveable sheave. Refer to specifications in front of this section for driven spring setting.
Page 166 CLUTCHING Assembly, Cont. Helix Angles and Effects The driven clutch helix was selected for overall performance in relation to the other driven system components. In fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift, we recommend trying a helix change before changing other components.
Page 167 CLUTCHING Assembly, Cont. 7. Install spacer washer(s), and snap ring. Snap ring should be installed with flat (machined) side up or toward jackshaft bearing. Preload 1/4 turn Snap Retainer Ring NOTE: Always install snap ring with chamfer towards helix (sharp edge out- ward) 8.
Page 168 CLUTCHING Installation 1. Install proper number of spacer washers on jackshaft between clutch and jackshaft bearing. Inspect Jackshaft Bearing Excessive vibration or abnormal drive belt wear can be caused by a worn bearing or jackshaft on the driven clutch side. To inspect bearing fit, watch the bearing area closely as you try to force the jackshaft up and down.
Page 169 CLUTCHING High Performance Roller Clutch Maintenance/ Adjustment 1. Remove clutch from vehicle. 2. Remove the screws that hold the helix in place. 3. Pull and twist upward to remove the helix from the clutch. Note: If changing helix angles move the helix 90_ to the desired combination and reinstall holding screws.
Page 170 CLUTCHING High Performance Roller Maintenance (cont.) 6. Remove the holding tool and remove the roller assembly. 7. Note the index slot for the roller assembly for installation. Index slot 8. Inspect spring for length. Inspect roller assembly for wear. Inspect shaft for nicks or burrs. 9.
Page 171 CLUTCHING Drive Belt Part No. Belt Width* Side Center Outer Notes (Projected) Angle Circum- Overall* Center* ference* 3211058 1.250 (31.75mm) 11.03 43.313 340 Touring and 340 Deluxe, P-90 system 3211059 1.250 (31.75mm) 12.00 45.125 P-90 system 3211060 1.250 (31.75mm) 45.605 P-90 system 3211042 1.375 (34.93mm)
Page 172: Drive Belt Inspection
CLUTCHING Drive Belt Inspection 1. Measure belt width and replace if worn severely. Generally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection. Projected Belt The top edges have been trimmed on some Width drive belts.
Page 173 CLUTCHING Belt Deflection Too much belt deflection - If the belt is too long or the Belt too high on initial engagement center distance too short, the initial starting ratio will be too high, resulting in performance loss. This is due to the belt rising too high in the drive clutch sheaves upon en- gagement.
Page 174 CLUTCHING Adjusting Belt Deflection Belt deflection can be adjusted without removing the clutch from the jackshaft. 1. Pull belt into driven clutch to slightly open sheaves. 2. Loosen three bolts on adjustment cam. 3. Turn cam counterclockwise to reduce distance between sheaves.
Page 175 CLUTCHING Adjusting Belt Deflection on the High Performance Roller 1. To adjust the sheaves, loosen the 7/16” jam nut on the belt witdth adjuster. 2. Using a 1/8” Allen wrench, adjust the threaded set screw as needed. NOTE: Turn the set screw in (clockwise) to increase the distance between the sheaves and out (counter clockwise) to decrease the distance.
Page 176 CLUTCHING Clutch Offset Inspection (ALL) Offset - Non-Electric Start Models NOTE: Proper offset aligns the fixed sheaves of both clutch assemblies. This allows the clutches to be No gap at aligned throughout the shift range. 5/8 Offset point “A” 1. Remove drive belt. Belt deflection adjustments All models with P85 driven clutch affect offset.
Page 177 CLUTCHING Clutch Alignment Inspection NOTE: Drive clutches are purposely misaligned slightly forward to compensate for the engine shifting on it’s mounts. Under load, the engine will pull back slightly so both clutches are in alignment. 1. After clutch offset has been verified, inspect alignment. 2.
Page 178 CLUTCHING Force belt to one side Belt to Sheave Clearance Inspection NOTE: The distance between the belt and the moveable sheave on the drive clutch is very important. This dis- tance controls the starting ratio (lowest starting ratio is most preferable) and the position of the clutch weight to engine RPM.
Page 179 KIT PN 2202376 Application Polaris snowmobiles with a wide roller spider Before you begin, read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information.
Page 180 CLUTCHING 9. Place the spider on the vise anvil and drive the roller pin through to the second land of the spider. NOTE: Care must be taken to ensure that the pin is started straight. Aluminum burrs could pass through into the roller bushing causing it to bind and stick.
Page 181 CLUTCHING SYMPTOMS PROBABLE CAUSE REMEDY Harsh drive clutch engage- -Drive belt worn too narrow -Replace ment -Excessive belt to sheave clearance with -Perform belt to sheave clear- new belt (high performance version with- ance adjustment with shim out detent shift weight) washers beneath spider Drive belt turn over -Wrong belt for application...
Page 182 CLUTCHING SYMPTOMS PROBABLE CAUSE REMEDY Engine RPM below specified a) Wrong or broken drive clutch spring a) Replace with recommended spring operating range, although en- b) Drive clutch shift weight too heavy b) Install correct shift weight kit to gine is properly tuned c) Driven clutch spring broken or installed match engine application in wrong helix location...
Page 183 440 Pro X Changes ........Gearing Matrix .
Page 185 CHASSIS/BRAKES/FINAL DRIVE 440 Pro X Bulkhead / Tunnel and Chassis changes New Seat Design Chaincase Improvements New Brake Rotor New Stronger Hollow Jackshaft...
Page 186 CHASSIS/BRAKES/FINAL DRIVE...
Page 187 CHASSIS/BRAKES/FINAL DRIVE...
Page 188 CHASSIS/BRAKES/FINAL DRIVE HYVOtSprocket Part Numbers Top Sprockets For 3/4 HYVOt Drive Systems 2900001 2900002 2900003 2900004 2900005 2900006 2900007 2900008 2900009 HYVOt Drive Chain Chain Length (Pitch) Part Number 3224071 3224070 3224069 3221110 3221109 3221108 Bottom Sprockets For 3/4 HYVOt Drive Systems Standard Bottom Sprockets Reverse Sprockets 2900010...
Page 189 CHASSIS/BRAKES/FINAL DRIVE Optional Tracks Length x Part Number Pattern/Lug Height Width 2900019 121 x 15 1.5 Deep Lug (Notched) 2900018 121 x 15 1.75 Deep Lug (Notched) 2900017 121 x 15 2 Deep Lug (Notched) 5411825 121 x 15 1 Mod Lightning 2872087 121 x 15 1.25 (Notched)
Page 190 CHASSIS/BRAKES/FINAL DRIVE Pro X Tunnels 2003 440 PRO X 2003 440 Fan / 600 / 700 / 800 PRO X...
Page 191 Hydraulic Brake System Operation View The Polaris snowmobile hydraulic brake system consists of the following components or assemblies: brake lever, master cylinder, hydraulic hose, brake caliper (slave cylinder), brake pads, and a brake disc which is secured to the drive line.
Page 192 5. Add brake fluid to within 1/4-5/16 (.6-.8 cm) of Polaris DOT 3 Brake Fluid reservoir top. PN 2870990 Polaris DOT 3 High Temp Fluid Reservoir Cover Screw Torque - (for Racing applications) PN 2873717 15-18 in. lb. (1.7-2 Nm) 6.
Page 193 CHASSIS/BRAKES/FINAL DRIVE Brake Bleeding - System Rebuild Brake Bleeding - Fluid Change, Cont. 13. Field test machine before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2 (1.3 cm) from handlebar. Brake Lever Reserve Limit Not less than 1/2 (1.3 cm) from handlebar...
Page 194 CHASSIS/BRAKES/FINAL DRIVE Brake System Wilwoodt Master Cylinder Cover Screws Cover Cover Gasket Parking Lever Spring Master Cylinder Screw Lever Pressure Switch Brake Line 10. Park Brake Lever 11. Reservoir Ring Hayest 1. Brake Caliper 2. Kit Bleeder Replacement 3. Brake Line 4.
Page 195 CHASSIS/BRAKES/FINAL DRIVE Step by Step instructions for Wilwood Master Cylinder Removal and Inspection. Disassembly 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 2. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt; remove bolt and sealing washers.
Page 196 CHASSIS/BRAKES/FINAL DRIVE Disassembly (cont.) 7. Remove reservoir screws and reservoir. Reservoir Bolts 8. Inspect reservoir seal and replace if worn or damaged. Clean surfaces of the reservoir and master cylinder body. Be sure compensating (A) and supply (B) ports are clean before reassembly. 9.
Page 197 CHASSIS/BRAKES/FINAL DRIVE Inspection 1. Clean the master cylinder assembly with clean Dot 3 brake fluid, brake parts cleaner, or denatured alcohol. Dry thoroughly. Inspect the bore for nicks, scratches or wear. Replace if damage is evident or if worn. 2. Inspect parking brake for wear. If teeth or locking cam are worn, replace lever. Assembly 1.
Page 198 CHASSIS/BRAKES/FINAL DRIVE Liquid Cooled Brake System Liquid Cooled Brake Pad Replacement 1. Carrier Bracket Attaching Bolts 2. Pistons 3. Piston Seals 4. Spring Clip 5. Brake Pads 6. Brake Line 7. Bleeder Screw 8. Caliper (Liquid Cooled) WARNING The rider’s safety depends on cor- rect installation.
Page 199 CHASSIS/BRAKES/FINAL DRIVE Rear Suspension Removal The Type 3 drive system is used on all models except the WideTrak. This system consists of a right side mounted chaincase with right side mounted brake assembly. 1. Turn OFF Fuel Valve and drain all the fuel from the fuel tank into an approved container.
Page 200 CHASSIS/BRAKES/FINAL DRIVE Rear Suspension Removal, Cont. 8. Remove three bolts, nuts, and washers securing angle drive and bearing flangettes. Remove and discard adaptor key. 9. Remove four suspension mounting bolts. 10. Place a protective mat on floor and tip machine onto left side.
Page 201 CHASSIS/BRAKES/FINAL DRIVE Chaincase Removal, Cont. 8. Remove three (PRO X has four) chaincase to bulkhead attaching nuts and bolts. The front bolt is a through bolt, rear and bottom bolts are carriage bolts. NOTE: On some machines it may be necessary to remove the rear exhaust bracket prior to lifting chaincase or remov- ing drive shaft assembly.
Page 202 CHASSIS/BRAKES/FINAL DRIVE Jackshaft Removal 1. Remove jackshaft. NOTE: On models with pressed bearing on jackshaft, shaft will have to be brought through bulkhead slot in order to re- move from unit. 2. Inspect drive shaft and jackshaft in bearing contact area.
Page 203 CHASSIS/BRAKES/FINAL DRIVE Chaincase Bearing Assembly 1. Apply Loctite 680 to outer race of new bearing and press into position. Press on outer race only, or bearing damage may result. 2. Reinstall snap rings. 3. Press new seals in until outer edge is flush with chaincase shoulder.
Page 204 CHASSIS/BRAKES/FINAL DRIVE Jackshaft Installation, Cont. 4. Insert jackshaft through bearing in chaincase 5. Install jackshaft alignment tool and secure with castle nut and flat washer. Tighten jackshaft nut securely to ensure positive bearing and jackshaft seating to chaincase. NOTE: Use of a standard nut and flat washer for this align- ment process will simplify the process as well as preserve the locking features of the lock nut for reassembly.
Page 205 CHASSIS/BRAKES/FINAL DRIVE Driveshaft Installation 1. Set track into machine making note of correct direction of travel. Most tracks have an arrow pointing which direction the track turns. 2. Insert driveshaft through bearing hole in bulkhead. Place inner driveshaft bearing flange bolts in the bulkhead.
Page 206 CHASSIS/BRAKES/FINAL DRIVE Driveshaft Installation, Cont. 6. Install chain tensioner. Finger tighten adjustment bolt. 7. Install brake caliper assembly in chaincase. CAUTION: On models with hydraulic brakes, make sure caliper piston is fully retracted into caliper to prevent brake binding from preload of pads. On models equipped with mechanical brakes make sure cam is fully re- tracted.
Page 207 Final Assembly Polaris Premium All Season Grease PN 2871423 1. Check speedometer cable routing. 2. Grease angle drive and bearing with Polaris grease. 3. Torque bottom chaincase sprocket bolt to Bottom Chaincase Sprocket Bolt Torque specification. 19 ft. lbs. (26.2 Nm) 4.
Page 208 Chaincase Cover Bolt Torque - 8 - 10 ft. lbs. (11 - 14 Nm) 7. Add 9 oz. (11 oz. on models equipped with reverse) of Polaris chaincase oil to the chaincase. Verify proper level with dipstick. Polaris Synthetic Gearcase Lube...
Page 209 CHASSIS/BRAKES/FINAL DRIVE Final Assembly, Cont. 10. Reinstall clutch offset washers on jackshaft and install driven clutch. Using the clutch alignment tool adjust driven clutch to achieve proper offset. See Clutch Offset Adjustment in this manual. Clutch Alignment Tool P90 - PN 2870914 P85 - PN 2870426 P90 Offset 21/32 : P90 Electric Start Offset: 1.28 (straight edge)
Page 210 CHASSIS/BRAKES/FINAL DRIVE Final Assembly, Cont. 15. Replace exhaust system. 16. Install hood, (if removed) aligning with marks made during disassembly. Ensure proper hood closure and readjust if necessary. Hood Bolt Torque - 8-10 ft. lbs. (11-14 Nm) 17. Test ride the unit to ensure all components are functioning properly before putting into service.
Page 211 440 Pro x Changes ........Springs .
Page 213 STEERING / FRONT SUSPENSION The following is a list of some improvements to the 2003 440 PRO X. Walker Evans Compression Adjustable Steering Post moved forward 2’ form 2003 IFS Shocks New Steering Bushing Improved Steering Geometry " Improved Steering Rack "...
Page 214 STEERING / FRONT SUSPENSION Spring Data Solid Length Wire Spring Rate Active Outside Spring Part # # Of Coils Length Diameter (in) Coils Diameter (in) (in) (lb/in) 7041203 2.21 0.060 20.70 18.70 0.367 1.280 38.6 7041204 13.00 0.438 11.00 9.00 3.590 5.250 7041253...
Page 215 STEERING / FRONT SUSPENSION Spring Data Continued Solid Length Wire Active Outside Spring Rate Spring Part # # Of Coils Length Diameter (in) Coils Diameter (in) (in) (lb/in) 7041698 4.00 0.225 5.84 3.84 2.350 1.310 7041699 4.00 0.235 5.75 3.75 2.370 1.350 7041701...
Page 216 STEERING / FRONT SUSPENSION...
Page 217 STEERING / FRONT SUSPENSION OPTIONAL IFS SPRINGS 7042090 10.5” x 195#/in 7042092 10.5” x 155 #/in 7041698 4.0” x 100 #/in 7041820 4.0” x 140 #/in 5133304 1” Transition spacer Front Track Shock (F/T) 7041680 7.0” x 140 #/in 7041827 7.0”...
Page 218 STEERING / FRONT SUSPENSION Torsion Bars Kits - 440 Pro X Fan, 440/600/700/800 Pro X, (42.5 max. width) Description Part Number 2900183 9/16 2900184 Adjustable Torsion Bar Assembly This assembly comes complete with all the necessary hardware to install. Slide in the aluminum block and then attach the torsion bar assembly.
Page 219 STEERING / FRONT SUSPENSION Front Suspension Setup and Adjustments Spring pre--load is one of the adjustment options which affects ride. Preload is the amount of pressure at which the spring is held. The longer the installed length of the spring, the less the amount of pre-load;...
Page 220 STEERING / FRONT SUSPENSION Springs Two types of springs are employed in Polaris suspen- sions, coil springs and torsion springs. Following is some of the terminology used when referring to coil springs. Free length - the length of a coil spring with no load ap- plied to the spring.
Page 221 STEERING / FRONT SUSPENSION Dual Rate Springs During initial compression of dual rate springs (two separate springs stacked on top of each other, both springs will compress resulting in an initial spring rate that is a combination of both springs, yet less than ei- ther of the individual springs.
Page 222 STEERING / FRONT SUSPENSION Torque Application List Due to the special grade bolts and nuts required for specific applications, observe the following torque values in the areas specified. Refer to exploded views for torque values and orientation of components and fasteners. 440 Pro X Fan, 440 / 600 / 700 / 800 EDGE Pro X Illustration depicts proper orientation of rod ends and bolts on steering components.
Page 223 Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store. Always use genuine Polaris parts and hardware when replacing front end components. Review steering adjustment guidelines on page 6.14 before making adjustments.
Page 224 STEERING / FRONT SUSPENSION Camber Definition - All IFS The following definitions of camber use automotive Positive, Negative, and Neutral (0 ) Camber terminology to describe positive and negative posi- tions. Refer to the illustration at right. 0 (Neutral) Camber - Spindle is 90 (perpendicu- lar) to ground + (Positive) Camber - Spindle bottom is canted inward toward chassis...
Page 225 The following information is to be used for 2003 Pro X Polaris Snowmobile front suspension setup. The data in the following table is based on the 2003 Pro X Polaris factory settings. Max- imum Width and Camber measurements are to be taken with the front end elevated and shocks at full extension.
Page 226 STEERING / FRONT SUSPENSION Prior to performing steering alignment, the suspension should be inspected for damage or wear and replacement parts installed as required. See inspection on page 6.11. WARNING A maximum set up width is listed in the chart on page 6.15. Maximum set up width is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended.
Page 227 STEERING / FRONT SUSPENSION Camber Adjustment 1. Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle. Remove the bar and install it through the other side to the opposite spindle. Measure from the top of the bar to the top of the hole.
Page 228 STEERING / FRONT SUSPENSION CAMBER INSPECTION All Models - Elevate Front End - Shocks Installed Typical CRC Shown - Style varies by model Suspension Free Hanging With IFS Shocks Installed Upper radius rod Lower radius rod Radius Rod End Jam Nuts Attaching Bolts Measure Here Refer to specifications for:...
Page 229 2. Center the handlebars by adjusting the drag link Drag Link length. Tighten the drag link jam nuts. 3. Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle. Torque ski bolts to specification. Install new cotter pin in castle nut.
Page 230 STEERING / FRONT SUSPENSION Toe Adjustment, All Models Lift 3-5 (7.6-12.7 cm) and work suspension to find average Toe adjustment on all models must be performed with the vehicle weight on the suspension, at Normal Ride Height. 1. Make sure the track is properly aligned. This will be used as a reference point for toe out measurement.
Page 231 STEERING / FRONT SUSPENSION STEERING ARM ORIENTATION FOR 440 Pro X Fan, 440 / 600 /700 / 800 Pro X Forward WARNING Correct As Close To Steering arm orientation is important to ensure proper 90 As Possible steering tie rod end thread engagement and steering performance.
Page 232 STEERING / FRONT SUSPENSION Arvin (IFP) IFS SHOCKS Extended Collapsed Shock Shock PN Stroke (in) IFP Depth (in) Shaft Part # Length (in) Length (in) Rod (in) 7042215 17.32 13.38 5.70 6.21 1700189 7042183 18.00 13.48 6.27 6.95 1700158 Walker Evans Racing Shocks (IFP) IFS SHOCK Extended Collapsed Shock...
Page 233 STEERING / FRONT SUSPENSION 440 Pro X Fan IFS Shock (Ryde FX) P/N 7042183 Ryde FX Shock - - PN 7042183 Shock Design Details (Inches) Travel ....6.27 Extended Length .
Page 234 STEERING / FRONT SUSPENSION 440 Pro X IFS Shock (Walker Evans Racing Shock) P/N 7042180 Ryde FX Shock - - PN 7042180 Shock Design Details (Inches) Travel ....6.27 Extended Length .
Page 235 STEERING / FRONT SUSPENSION 600/700/800 Pro X IFS shock (Ryde FX) P/N 7042215 Ryde FX Shock - - PN 7042215 Shock Design Details (Inches) Travel ....6.21 Extended Length .
Page 237 440 Pro X Changes ........Suspension Torque Specifications .
Page 239 REAR SUSPENSION/TRACK/TRACTION Pro X Rear Suspension Improvements H Walker Evans Racing Shocks Improved Front Torque Arm design New 1 5/8” “SNO X” Pattern Track...
Page 240 REAR SUSPENSION/TRACK/TRACTION Suspension Torque Specifications 3/8 suspension mounting bolts ....... 35 - 40 ft.
Page 241 REAR SUSPENSION/TRACK/TRACTION Rear Suspension Operation The primary function of the rear suspension is to provide a comfortable ride in all types of riding conditions. It separates the rider from the ground, while allowing for complete vehicle control. The rear suspension also must provide weight transfer and maintain track tension.
Page 242 REAR SUSPENSION/TRACK/TRACTION Springs Two types of springs are employed in Polaris suspen- sions, coil springs and torsion springs. Following is some of the terminology used when referring to coil springs. Coil Spring Free length - the length of a coil spring with no load ap-...
Page 243 REAR SUSPENSION/TRACK/TRACTION Rear Suspension Tuning Many factors influence the overall handling characteristics of snowmobile suspensions. Rider weight, riding style, course conditions, and the condition of suspension components are some of the things that you have to consider when tuning a suspension. On new machines, or whenever new suspension parts are installed, the sled should be ridden for at least one tank of fuel to allow moving parts in the shocks and suspension to wear in.
Page 244 REAR SUSPENSION/TRACK/TRACTION Shock Valving To check high speed rebound, drive over a series of fairly large moguls. Gradually increase the speed until you reach 70% to 80% of maximum vehicle speed or the maximum safe speed for the vehicle over those bumps. (The reason for limiting speed is that it is difficult to feel what the shocks are doing when you are driving at full speed.) Ideal high speed rebound is achieved when your suspension keeps returning fast enough to have full travel as...
Page 245 REAR SUSPENSION/TRACK/TRACTION Shock Valving The valving piston has six large compression holes Rebound holes and three smaller rebound holes. The smallest hole, Piston called the low speed hole, controls low speed rebound damping. It also has about a 25% effect on low speed compression.
Page 246 REAR SUSPENSION/TRACK/TRACTION Shock Valving Arrangement Shown below is an example of how valving stacks are arranged. The following diagrams will have the compression and rebound stacks listed as if the shock rod is in a vise and the nut end is facing upward. Parts in box are an example of standard valving.
Page 247 REAR SUSPENSION/TRACK/TRACTION REAR SUSPENSION SHOCKS Front Shock Specifications Ryde FX FRONT TRACK SHOCKs Extended Collapsed IFP Depth Shock PN Travel (in) Shaft Part # (in) Length (in) Length (in) (in) 7042205 11.98 8.24 3.74 Emulsion 1700214 7042214 11.99 8.24 3.75 1.50 Walker Evans Racing Shocks FRONT TRACK SHOCKS Extended...
Page 248 REAR SUSPENSION/TRACK/TRACTION Front Track Shock - 440 Pro X Fan - - Ryde FX P/N 7042205 Walker Evans Racing Shock - - PN 7042205 Shock Design Details (Inches) Travel ....3.74 Extended Length .
Page 249 REAR SUSPENSION/TRACK/TRACTION Rear Track Shock - 440 Pro X Fan - - Ryde FX P/N 7042184 Walker Evans Racing Shock - - PN 7042184 Shock Design Details (Inches) Travel ....5.35 Extended Length .
Page 250 REAR SUSPENSION/TRACK/TRACTION Front Track Shock - 440 Pro X - - Walker Evans Racing P/N 7042178 Walker Evans Racing Shock - - PN 7042178 Walker Evans Racing Shock - - PN 7042178 Shock Design Details (Inches) Shock Design Details (Inches) Travel Travel .
Page 251 REAR SUSPENSION/TRACK/TRACTION Rear Track Shock - 440 Pro X - - Walker Evans Racing P/N 7042179 Walker Evans Racing Shock - - PN 7042179 Shock Design Details (Inches) Travel ....6.27 Extended Length .
Page 252 REAR SUSPENSION/TRACK/TRACTION Front Track Shock - 600/700/800 Pro X - - Ryde FX P/N 7042214 Walker Evans Racing Shock - - PN 7042214 Shock Design Details (Inches) Travel ....3.75 Extended Length .
Page 253 REAR SUSPENSION/TRACK/TRACTION Rear Track Shock - 600/700/800 Pro X - - Ryde FX P/N 7042213 Walker Evans Racing Shock - - PN 7042213 Shock Design Details (Inches) Travel ....5.35 Extended Length .
Page 254 REAR SUSPENSION/TRACK/TRACTION Walker Evans Racing Shocks Rear Shock Maintenance (IFS Shock Shown) Disassembly 1. Remove shock from vehicle and clean thoroughly. 2. Remove button head hex screw (A) from reservoir end cap. 3. Insert safety needle carefully and depress the center of the Schrader valve to de-pressurize.
Page 255 REAR SUSPENSION/TRACK/TRACTION Valve Stack Maintenance 11. Place shock rod in the vise by the upper eyelet. 12. Remove the lock nut from the shock rod. 13. Place the valve stack on a clean shop towel. NOTE: Make sure to place the valve stack on a shop towel in the order that you remove them.
Page 256 REAR SUSPENSION/TRACK/TRACTION Walker Evans Racing Shocks Rear Shock Maintenance (Cont.) 21. Fill the shock body and the reservoir 1/2 full of Walker Evans 5w shock oil (PN 2874522). 22. Apply a thin film of oil to the IFP O-ring and floating wear band.
Page 257 REAR SUSPENSION/TRACK/TRACTION Walker Evans Racing Shocks Valve Part Numbers. Ryde FX Part umbers on page 7.28 PART NUMBER ... . SIZE 1800050 ....065x.625 1800051 .
Page 258 REAR SUSPENSION/TRACK/TRACTION Ryde FX Shock Maintenance Procedures for the proper disassembly and assembly of Ryde FX gas charged IFP and emulsion mono--tube shock absorbers. WARNING: Before servicing a gas shock it is important that all the gas pressure be discharged from the unit. Refer to the instructions listed below for the proper procedure of discharging the gas pressure from a shock.
Page 259 REAR SUSPENSION/TRACK/TRACTION B) Emulsion Shocks: With the shock inverted and the piston rod fully extended, secure the lower mount of the shock in a vise. Allow a couple of minutes for the gas pressure to separate from the oil and rise to the top.
Page 260 REAR SUSPENSION/TRACK/TRACTION Flats Place the shock piston rod upper mount in bench vise, begin piston and valve removal. Arrange parts re- moved in the sequence of disassembly. The piston should have the flat slots facing the nut end (as high- lighted in black).
Page 261 REAR SUSPENSION/TRACK/TRACTION Apply a thin film of oil onto the floating wear band and O--ring and install the floating piston into the top of the shock body, positioning it below the counterbore. (PICTURE 13) Using the tool as a handle, push the floating piston down into the shock body, being careful not to damage I.F.P wear band and O--ring, until the val- ue indicator knob comes in contact with the shock...
Page 262 REAR SUSPENSION/TRACK/TRACTION With the cylinder head assembly pushed down against the piston, carefully, insert the piston rod and assembly into the cylinder; Slightly oscillating the piston rod to allow piston to enter shock body bore. A light coating of oil on the piston wear band will ease installation.
Page 263 REAR SUSPENSION/TRACK/TRACTION Procedures for the proper disassembly and assem- bly of the adjustable compression clicker WARNING: Before servicing a gas shock it is impor- tant that all the gas pressure be discharged from the unit. Refer to the instructions listed below for the proper procedure of discharging the gas pressure from a shock.
Page 264 REAR SUSPENSION/TRACK/TRACTION Remove the compression head from the clicker as- sembly housing by grasping the compression pin with pliers and pulling straight out. (Picture 25) ASSEMBLY:Install the compression head into the clicker assembly housing, making sure the com- pression pin is facing up. (Picture 26) Fill compression housing with approximately 10cc of shock fluid.
Page 265 REAR SUSPENSION/TRACK/TRACTION Pressurize the shock reservoir, through the pres- sure valve, with nitrogen gas to the specified pres- sure. (PICTURE 29) If using Ryde FX inflation tool Refer to Procedures for use of replaceable inflation Needle instruction manual found in Ryde FX Inflation Tool case. NOTE: -- Depending on which shock absorber is be- ing worked on, adjust the gas pressure the specified value indicated in the shock specification chart lo-...
Page 266 REAR SUSPENSION/TRACK/TRACTION Ryde FX Valve Washer Part Numbers Walker Evans Part Numbers on pg 7.19. Polaris # Thickness Diameter 1700080 0.004 .700 1700081 0.006 .700 1700082 0.008 .700 1700083 0.010 .700 1700084 0.012 .700 1700085 0.015 .700 1700086 0.004 .800 1700087 0.006...
Page 267 REAR SUSPENSION/TRACK/TRACTION Suspension Lubrication 7.29...
Page 268 REAR SUSPENSION/TRACK/TRACTION Rear Suspension Components - Pro X Rear Xtra Travel Arm (XTA) Rear Track Shock Limiter Strap Rear Torque Front Track Shock Rear Torsion Spring Rear Shock Reservoir Rear Torsion Spring Forward Carrier Wheel Rear Track Shock Front Torque Arm Idler Wheel Limiter Strap...
Page 269 REAR SUSPENSION/TRACK/TRACTION Rear Suspension Exploded View - Pro X Style Pro X Front Torque Arm Pro X Rear Torque Arm Pro X Rear Suspension rail assembly 7.31...
Page 270 REAR SUSPENSION/TRACK/TRACTION Track Tension Tension adjustments should be made only after the track is warmed up and limber. Always inspect track alignment after track tension adjustment. 1. Turn the machine off. 2. Lift the rear of the machine and safely support it off the Hi-fax ground.
Page 271 Hi-Fax Inspection / Replacement Hi Fax Wear Limit Hi-Fax Replacement - All Models Hi-Fax replacement on all Polaris models is similar. When any area of the Hi-Fax is worn to 1/8 (.3 cm.), it 7/16 (1.1 cm.) should be replaced. This will save wear on other vital components.
Page 272 XTRA Lite Wide Hi-Fax Xtra Lite wide hi-fax is available for ice racing applications. The part number is 5521587- -309 for 2003 Pro X suspensions. Install with the wide side to the outside of the snowmobile. These hi-fax are made with a wear mark on the outside.
Page 273 REAR SUSPENSION/TRACK/TRACTION Traction The amount of traction required varies depending upon the type of riding and the snowmobile’s horsepower. Studs are designed specifically for each riding category. They’re made in various lengths, shapes, and materials. Improperly applied studs can cause poor traction and premature wear. Studs which are too long can cause dam- age to the tunnel and heat exchangers.
Page 274 REAR SUSPENSION/TRACK/TRACTION Stud Installation 1. Mark the stud pattern on the track. 2. Drill stud holes with a 1/4 (7mm) hollow-core drill bit. Make sure the drill is sharp for a clean hole. 3. Spin the non-cutting portion of the drill shank in the hole at high speed to melt the cords together, or melt them with a 1/4-9/32 heated probe.
Page 275 As a rule of thumb, the more studs, the longer and sharper the carbide on the skags should be. The recommenda- tions in the chart should be used as guidelines in achieving a proper balance of ski and track traction products on Polaris snowmobiles. Typical pattern placement...
Page 276 REAR SUSPENSION/TRACK/TRACTION Traction Too few studs will allow the track to spin, resulting in excessive wear or damage to the studs. A loose condition can result from too many dull studs. Front end pushing can result from too many sharp studs. After studs are installed, it’s important to install carbide skags to ensure maximum steering control.
Page 277 Engine Electrical ........Degrees to Piston Position .
Page 279 ELECTRICAL Engine Electrical Machine Alternator Spark Plug Plug Gap CDI Box Fly- Model Model Wattage Wattage MM/Inches MM/Inches Identification Identification wheel wheel Champion Number ID # BR9ES RN2C 0.7/.028 CU7227 IG3792 440 Pro X Fan RN57YCC 0.7/.028 4010624 4010624 440 Pro X RN57YCC 0.7/.028 4010689...
Page 280 ELECTRICAL Conversion Chart - Degrees to Piston Position - B.T.D.C. If the ignition timing specification is listed in degrees only, convert to either inches or mm BTDC and use a dial indicator to verify timing marks. NOTE: Due to differing rod lengths and engine strokes, consult the engine model list for correct engine.
Page 281 ELECTRICAL Twin Cylinder Fan CDI Ignition - Exploded View - Timing 440 Pro X Fan Stator 240 Watt System RFI Caps CDI System Ignition Coil NOTE: Always verify timing of engine at room temperature only (68 F / 20 C, no engine warm up) and at the proper RPM.
Page 282 ELECTRICAL Exploded View - Timing 440/600 Pro X Stator Flywheel RFI Cap Dragon Switch 280 Watt System 440 Pro X only Ignition Coil NOTE: Always verify timing of engine at room temperature only (68 F / 20 C, no engine warm up) and at the proper RPM.
Page 283 ELECTRICAL 700 / 800 Pro X Stator Plate Flywheel Housing Flywheel Exciter Water / Oil Pump Drive Belt RFI Cap Lighting Coil CDI Control Unit Wiring Harness 280 Watt Charging System NOTE: Always verify timing of engine at room temperature only (68 F/20 C). Acceptable Variance Flywheel Flywheel Lines...
Page 284 ELECTRICAL CDI Ignition Timing Timing Procedure - All Models NOTE: Always verify timing of engine at room temperature only (68 F / 20 C, no engine warm up) and at the proper RPM. 1. Refer to the timing specification charts at the beginning of this section to determine the proper ignition timing for the engine you are working on.
Page 285 ELECTRICAL Stator Diameter Retard Crankcase Mark Stator Mark Stator Plate Advance The formula for determining stator movement per degree of timing: Diameter of stator x 3.1416 = thousandths of stator movement per degree of timing 4.000 x 3.1416 Example: = .035 of stator movement per one degree of stator movement Ignition System Testing Ignition system components can be individually tested by measuring their internal resistance and insulation to ground.
Page 286 Volts and Ohms quality multitester will work. However, due to ease of opera- Dial tion and durability, Polaris recommends the Fluke Model 73 (PN 2870659), or Tektronix DMM155. See photo at right. This instrument will provide a digital readout of the measured value of the test being performed.
Page 287 ELECTRICAL Multimeter Usage = Ohms, resistance - measuring component resistance values - testing coils, wiring, etc. Used to test resistance to the flow of electricity in a circuit or component. A reading of OL means an open circuit or infinite resistance.
Page 288 ELECTRICAL Unregulated Voltage - continued 7. Turn the multitester dial to the Volts AC (Vµ) position. 8. Disconnect the alternator to main harness connector at engine. 15-45 9. Connect one of the tester leads to the yellow alternator wire and the other lead to the brown alternator wire. NOTE: On floating alternators, the yellow/red stator wire should connect to the brown stator wire.
Page 289 Refer to the following text for applications. Polaris Snowmobiles: All Polaris Domestic twin cylinder engines ......
Page 290 ELECTRICAL Exhaust System Temperature sender - 440 Pro X Temp sender The temp sender that is on the 440 Pro X will read the exhaust temperature and adjust the timing according to the temperature range. To Test the sensor: Unplug sensor. At room temperature the temperature sender will have a HIGH resistance (may read Open Line (OL)) depending on your meter.
Page 291 ELECTRICAL Headlight Bulb Filament Continuity Test 1. Turn the Multitester dial to the ohms ( ) position. 2. Disconnect the wire harness from the headlight bulb. 3. Viewing the back of the bulb with the terminal blades at the 9, 12 and 3 o’clock position, connect the black multitester lead to the 9 o’clock blade.
Page 292 ELECTRICAL Ignition Switch Testing (Non-Electric Start) 1. Set the multitester dial to the ohms ( ) position. Connect one of the tester leads to either of the switch terminals and the other tester lead to the other switch terminal. 2. With the switch off, the reading should be less than .4 ohms.
Page 293 Polaris DRAGONt Ignition Operation Your 2003 Polaris 440 Pro--X snowmobile is equipped with an ignition--system feature which improves competi- tion performance by increasing exhaust--system temperature. The Dragont ignition system provides maximum ”holeshot”...
Page 294 ELECTRICAL Speed Control Assurance Operation Insulator Off Idle Switch Auxiliary Kill Switch Contacts Ignition Primary Conductor Plungers Outward Idle Switch Engine Ground Throttle Control Cutaway The speed control assurance consists of two series connected switches. If one or both switch plungers are posi- tioned inward, the circuit is open and the engine will run.
Page 295 ELECTRICAL Speed Control Assurance Testing 1. Set the multitester in the ohms ( ) position. 2. Disconnect the switch harness from the main wire harness. 3. Connect the two multitester leads to the two switch wires. Test 1 - Open Circuit - Run With the auxiliary shut-off switch in the ON position, the multitester should read an open circuit (OL).
Page 296 However, upon removal of the TPS, you must mark the TPS position on the carburetor and replace it in the exact same position as removal. Polaris has developed a TPS test kit for aid in setting the Throttle Position Sensor to specification.
Page 297 O.L. mometarily when throttle is opening. 6. Voltage at yellow terminal should be 4.0 volts at Wide Open Throttle for domestic engines, If not, the TPS must be adjusted. TPS Volts at Wide Open Throttle - Polaris Domestic Engines: 4.0 - - 4.2 Volts 8.19...
Page 298 2. Turn the TPS clockwise to decrease voltage, or counterclockwise to increase voltage. Increase Decrease 3. When the TPS is set to the desired voltage, tighten the holding screws and verify voltage is 4.0 --4.2 volts at Wide Open Throttle for Polaris domestic engines. 8.20...
Page 299 ELECTRICAL TPS Adjustment - Continued 4. When the TPS is set and voltage is verified, remove the tester and re-install the snowmobile TPS harness. 5. When storing the TPS tester, remove the red terminal of the tester and insert it in the blank terminal of the harness.
Page 300 ELECTRICAL Condition: No Spark Disconnect the single black (black/white) wire from the CDI Module to Check the ignition switch, wire harness, throttle safety switches the ignition kill circuit. Does it have a spark? and kill switch for proper adjustment or short to ground. Repair Yes! or replace as necessary.
Page 301 ELECTRICAL Wiring Diagram - 440 Pro X Fan 8.23...
Page 302 ELECTRICAL Wiring Diagram - 440 Pro X 8.24...
Page 303 ELECTRICAL Wiring Diagram - 600/700/800 Pro X 8.25...
Page 305 Numbers Carburetor Starter System, 3.9 Chain Case Removal, 5.16 440 Pro X Fan, Specifications, 1.4–1.6 Chaincase Bearing Removal, 5.17 440 Pro X, Specifications, 1.6–1.8 Choke Adjustment, 3.29 600 Pro X, Specifications, 1.8–1.10 Clutch Alignment Adjustment, 4.45 700 Pro X, Specification, 1.10 Clutch Alignment Inspection, 4.45 800 Pro X, Specifications, 1.12 Clutch Offset Adjustment, 4.44...
Page 306 Drive Clutch Installation, 4.28, 4.29 Fox Shock Maintenance, 7.20 Drive Clutch Operation, 4.17 Rear Track Shock Specifications, 7.9 Fron Suspension Shock Suspension Specifications, Drive Clutch Puller Chart, 4.1 Drive Clutch Removal, 4.21 Front Track Shock, 440 Pro X, 7.12 Drive Clutch Service Tools, 4.1 Front Track Shock, 440 Pro X Fan, 7.10 Drive Clutch Spring Data, 4.7, 4.8, 4.9 Front Track Shock, 600/700/800 Pro X , 7.14...
Page 307 IFS Shock, 440 Pro X , 6.22 IFS Shock, 600/700/800 Pro X, 6.23 Pilot Air Screw, 3.10 Ignition Switch Testing, 8.14 Pilot Jet, 3.10 Ignition System Testing, 8.7 Pilot Jet Part Numbers, TMX, 3.3 Piston Inspection/Measurement, 2.56 Piston Pin Inspection, 2.49 Piston Ring Installation, 2.56 Jackshaft Installation, 5.19 Piston Ring Installed Gap, 2.56...
Page 308 Spider Indexing, 4.20 TPS Adjustment, 8.20, 8.21 Spider Roller Installation, 4.24, 4.25 TPS Testing, 8.18, 8.19 Spider Roller Removal, 4.24 Track Clip Replacement, 7.34 Spindle Centering, IFS, 6.14 Optional Tracks, 5.5 Spring Data, 6.2–6.4 ISR Optional Tracks, 5.5 Springs, Dual Rate, 6.9 Traction, 7.35, 7.37, 7.38 Sprocket Part Numbers, 5.4 Trail Set Up, 92 Octane Fuel, 1.2...
Page 309 PN 9918053 Printed in USA...

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