Polaris 2003 Pro X Service Manual page 18

GENERAL INFORMATION
MODEL: . . . . . . . . . .
MODEL NUMBER:
ENGINE MODEL:
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 . . . . . . .0787 (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) 1.438 (36.52mm) .
Side Angle (Overall) . . 28
Outside Circumference 46.625
Center Distance . . . . . . 11.50
Shift Weights . . . . . . . . 10-64
Primary Spring . . . . . . . Black/Green
Secondary Spring . . . . Black/Red
Driven Helix . . . . . . . . . Team 62--46/.46
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . .
Piston / Cylinder Clearance
Service Limit . . . . . . . . . . . . . . . .
Piston Marking . . . . . . . . . . . . . .
Piston Ring Marking . . . . . . . . .
Piston Ring End Gap
Head ccs (Uninstalled)
Head ccs (Installed) . . . . . . . . .
Operating RPM 200 . . . . . . . . .
Idle RPM 200 . . . . . . . . . . . . . .
Engagement RPM 200
Cylinder Head Torque
Cylinder Base Nut Torque
Crankcase Torque (10mm)
Flywheel Torque . . . . . . . . . . . . .
1.12
800 PRO X
. S03NX8CS
. . S2398- -8070PA8C
Altitude ltitude
Meters Meters
(Feet) (Feet)
Liquid Cooled Case Reed Twin
794cc
3.3464 (85mm)
2.7559 (70mm)
. . . 0.006 - 0.0074 (0.15 - 0.188mm)
0.0074" (0.188mm)
3021184
N/A
. . . . . . . . 0.016 - 0.022 (0.41 - 0.56mm)
. . . . . . . 45.7 0.5cc
32.2 0.5cc
8000 RPM
1400 RPM
. . . . . . 3800 RPM
. . . . . . . . 18-22 ft.lbs. (25-30 Nm)
. . . . 30-34 ft.lbs. (41-47 Nm)
. . . 26-30 ft.lbs. (36-41 Nm)
90 ft.lbs. (124 Nm)
JETTING CHART
Below -30 F
-30_ to - -10_F
Below -34 C Below 34 C
-34 to -23 C -34_to -23_C
0- -600 490 470
(0- -2000)
#5 #4
600- -1200 460 440
(2000- -4000)
#4 #4
1200- -1800 1200- -1800
430 430 410 410
(4000- -6000)
#4 #4
1800- -2400 410 390
(6000 8000) (6000- -8000)
#4 #4 #3 #3
2400- -3000 380 360
(8000- -10000) (8000 10000)
#3 #3 #3 #3
3000- -3700 350 330
(10000 12000) (10000- -12000)
#3 #3 #3 #3
XXX
#X
- # refers to the clip position from top of jet needle.
CLUTCH CHART
Altitude ltitude
Weight
Meters Meters
0-900 0-900
10 64 10-64
(Feet)
(0-3000)
900-1800 900-1800
10 62 10-62
(3000-6000)
1800-2700 1800-2700
10-60 10 60
(6000-9000)
2700-3700 2700-3700
10-58 10 58
(9000-12000)
- Production Setting
Fuel Pump Manuf.
Fuel Pump Mark
Oil Pump Manuf.
Oil Pump Mark
Cylinder Head Mark
AMBIENT TEMPERATURE
- -10_to +10_F +10_to +30_F +30_to +50_F
-23 to - -12 C -23_ to - -12_C -12 to - -1 C -12_to - -1_C -1 to +10 C -1_to +10_C
450 430
#4 #4
420 410
#4 #3
400 400 380 380
#3 #3
370 350
#3 #3 #3 #3
340 320
#3 #3 #3 #3
320 300
#3 #3 #2 #2
DRIVE DRIVEN
Shift Shift Clutch Clutch Clutch Clutch
Spring Spring
62- -46/ 62- -46/
Bl ck/ ree Black/Green Bl ck/Red Black/Red
62- -46/ 62- -46/
Bl ck/ ree Black/Green Black/Red Bl ck/Red
62- -44/ 62- -44/
Bl ck/ ree Black/Green Bl ck/Red Black/Red
62- -44/ 62- -44/
Bl ck/ ree Black/Green Black/Red Bl ck/Red
. . . . . N/A
. . . . . . . N/A
. . . . . . . Mikuni
. . . . . . . . 2540102
. . . . 3021324
Above +50_F
Above +10_C Above +10 C
410 400
#3 #3
390 370
#3 #3
360 360 340 340
#3 #3
330 320
#3 #3 #2 #2
310 290
#2 #2 #2 #2
280 260
#2 #2 #2 #2
Chaincase Chaincase
Driven Driven
Helix
Gearing
25-40 76P 25-40 76P
.46 HYVO
25-41 76P 25-41 76P
.46 HYVO
23-39 74P 23-39 74P
.46 HYVO
23-39 74P 23-39 74P
.46 HYVO