Pro - Polaris 2003 Pro X Service Manual

GENERAL INFORMATION
MODEL: . . . . . . . . . .
MODEL NUMBER:
ENGINE MODEL:
CARBURETION
Type . . . . . . . . . . . . . . . .
Main Jet . . . . . . . . . . . .
Pilot Jet . . . . . . . . . . . . .
Jet Needle . . . . . . . . . . .
Needle Jet . . . . . . . . . . .
Cutaway . . . . . . . . . . . .
Air Screw . . . . . . . . . . .
Valve Seat . . . . . . . . . . .
Starter Jet . . . . . . . . . . .
Fuel Octane w/o Ethanol 110 Oct.minimum
Throttle Gap
Under Cutaway . . . . . .
Exhaust Valve Spring
CLUTCH
Type . . . . . . . . . . . . . . . .
Belt . . . . . . . . . . . . . . . . .
Belt Width (Projected) 1.438 (34.93mm) .
Side Angle (Overall) . .
Outside Circumference 46.625" (118.43cm..)
Center Distance . . . . . .
Shift Weights . . . . . . . .
Primary Spring . . . . . . .
Secondary Spring . . . .
Driven Helix . . . . . . . . .
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . .
Piston / Cylinder Clearance
Service Limit . . . . . . . . . . . . . . . .
Piston Marking . . . . . . . . . . . . . .
Piston Ring Marking . . . . . . . . .
Piston Ring End Gap . . . . . . . .
Operating RPM 200 . . . . . . . . .
Idle RPM 200 . . . . . . . . . . . . . .
Engagement RPM 300
Cylinder Head Torque . . . . . . . .
Cylinder Base Nut Torque
Crankcase Torque (8mm)
Crankcase Torque (10mm)
Flywheel Torque . . . . . . . . . . . . .
1.6
440 PRO X
. S03NX4CS
. . S2424- -4460PA4C
Altitude ltitude
TMX-34 Mikuni
290
35
6GL67--61--3
Q-8 (Fixed)
Meters Meters
2.5
(Feet) ( )
.5 Turns
1.5 Viton
1.5
.098 (2.5 mm)
Red/White
P--85
3211080
28
11.5 (305mm)
S--51H
Almond/Red
Red/Blue 140/200
70/44 -- .46
(66/44 -- .46)
Liquid Cooled Case Reed w/V.E.S.
438 cc
2.598 (66mm)
2.520 (64mm)
. . . 0.0023 - 0.0037 (0.06 - 0.095mm)
0.0059 (0.15mm)
EK2185/28
3021303
.012 -.018 (.30-.45mm)
8500 RPM
1500 RPM
. . . . . . 5500 RPM
20-24 ft.lbs(2.8-3.3 kgm)
. . . . 30-34 ft.lbs(4.15-4.7 kgm)
. . . . . 20-24 ft.lbs(2.8-3.3 kgm)
. . . N/A
90 ft.lbs(12.4 kgm)
JETTING CHART FOR 110 OCTANE
Below -30 F -30_ to - -10_F
Below -34 C Below 34 C
-34 to -23 C -34_to -23_C
0- -600 310 300
(0- -2000)
#3 #3
600- -1200
300 280
(2000- -4000)
#3 #3
1200- -1800 1200 1800 280 280 270 270
( 000 6000) (4000- -6000)
#3 #3
1800- -2400 260 260 250 250
(6000 8000) (6000- -8000)
#3 #3
2400- -3000 240 0 230 30
(8000 10000) (8000- -10000)
#2 #2
3000- -3700 230 30 210 0
(10000- -12000) (10000 12000)
#2 #2
XXX
#X
- # refers to the clip position from top of jet needle.
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
Altitude ltitude
Weight
Meters Meters
0-900 0-900
S 51H S- -51H
(Feet)
(0-3000)
900-1800 900-1800
S- -49H S 49H
(3000-6000)
1800-2700 1800-2700
S- -47H S 47H
(6000-9000)
2700-3600 2700-3600
S 45H S- -45H
(9000-12000)
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
290 280
#3 #3
270 260
#3 #3
260 260 240 240
#3 #2
240 240 230 230
#2 #2
220 0 210 0
#2 #2
200 00 190 90
#2 #2
DRIVE DRIVEN
Shift Shift Clutch Clutch Clutch Clutch Driven Driven
Spring Spring Helix
Almond Almond 140/200 140/200 70/44 70/44
Red Red/Blue .46
Almond Almond 140/200 140/200 70/44 70/44
Red Red/Blue .46
Almond Almond 140/200 140/200 70/44 70/44
Red Red/Blue .46
Almond Almond 140/200 140/200 62/40 62/40
Red Red/Blue .46
Above +50_F
Above +10 C Above +10_C
270 260
#2 #2
250 240
#2 #2
230 230 220 220
#2 #2
210 210 200 200
#2 #2
200 00 190 90
#2 #2
180 80 170 0
#2 #2
Chaincase Chaincase
Gearing
19:43 19:43
74P
19:43 19:43
74P
19:43 19:43
74P
19:43 19:43
74P