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 . . . . . . . . . . .
Fuel Octane (R+M/2) .
Throttle Gap
Under Cutaway . . . . . .
Pilot Air Jet . . . . . . . . . .
Starter Jet . . . . . . . . . . .
Fuel Screw . . . . . . . . . .
Exhaust Valve Spring .
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 . . . . . . . . 10-58
Primary Spring . . . . . . . Dark Blue/White
Secondary Spring . . . . Red/Dark Blue
Driven Helix . . . . . . . . . Team 58--42 /.46
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . .
Piston / Cylinder Clearance
Piston Marking . . . . . . . . . . . . . .
Piston Ring Marking . . . . . . . . .
Piston Ring End Gap
Head ccs (Uninstalled)
Head ccs (Installed) . . . . . . . . .
Operating RPM 200 . . . . . . . . .
Idle RPM 100 . . . . . . . . . . . . . .
Engagement RPM 200
Cylinder Head Torque
Cylinder Base Nut Torque
Crankcase Torque (8mm)
Crankcase Torque (10mm)
Flywheel Torque . . . . . . . . . . . . .
1.8
600 PRO X
. S03NX6ES
. . S2392- -6044PA6E
TM 38 Mikuni w/TPS
440
Altitude ltitude
40
9DFH1-60-2
P-8
2.0
N/A
1.5 Viton
Meters Meters
87 Non-Oxygenated
(Feet) (
89 OxygenatedKey
Switch Adj.
.079 (2.0mm)
.9
140
1.5 Turns
Green/Yellow
Liquid Cooled Case Reed w/VES
593cc
3.041 (77.25mm)
2.520 (64mm)
. . . .0045 -.0059 (.11-.15mm)
3021308
N/A
. . . . . . . . .014 -.020 (.38-.51mm)
. . . . . . . N/A
N/A
8000
1200
. . . . . . 4000
. . . . . . . . 20-24 ft.lbs. (28-33 Nm)
. . . . 30-34 ft.lbs. (41-47 Nm)
. . . . . 20-24 ft.lbs. (28-33 Nm)
. . . N/A
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
480 460
(0- -2000)
#3
600- -1200 450 430
(2000- -4000)
#2
1200- -1800 1200 1800
420 420 400 400
(4000- -6000) ( 000 6000)
) #2
1800- -2400 400 00 380 380
(6000 8000) (6000- -8000)
#2 2
2400- -3000 3 0 370 350 350
(8000- -10000) (8000 10000)
#2 2
3000- -3700
340 3 0 330 330
(10000 12000) (10000- -12000)
#1 1
XXX
#X
- # refers to the clip position from top of jet needle.
CLUTCH CHART
Altitude ltitude
Meters Meters
0-900 0-900
(Feet)
(0-3000)
900-1800 900-1800
(3000-6000)
1800-2700 1800-2700
(6000-9000)
2700-3700 2700-3700
(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
-23 to - -12 C -23_ to - -12_C -12_to - -1_C -12 to - -1 C
440 420
#2 #2 #2
410 400
#2 #2 #2
390 390 370 370
#2 #2 #1
360 360 3 0 340
#2 2 #1 1 #1 1
330 330 3 0 320
#1 1 #1 1 #1 1
3 0 310 290 90
#1 1 #1 1 #1 1
DRIVE
Shift Shift Clutch Clutch Clutch Clutch
Weight Spring Spring
Dark Blue / Dark Blue / Red/ Dark Red/ Dark
10-58 10 58
White Blue
Dark Blue / Dark Blue / Red/ Dark Red/ Dark
10 56 10-56
White Blue
Dark Blue / Dark Blue / Red/ Dark Red/ Dark
10-54 10 54
White Blue
Dark Blue / Dark Blue / Red/ Dark Red/ Dark
10 10
White Blue
. . . . . N/A
. . . . . . . N/A
. . . . . . . Mikuni
. . . . . . . . 2540097
. . . . 3021320
+30_to +50_F Above +50_F
-1 to +10 C -1_to +10_C Above +10 C Above +10_C
400 390
#2 #1
380 360
#1 #1
350 350 330 330
#1 #1
330 330 320 3 0
#1 1 #1 1
300 300 280 80
#1 1 #1 1
270 0 260 60
#1 1 #1 1
DRIVEN
Chaincase Chaincase
Driven Driven
Helix
Gearing
23-39 74P 23-39 74P
58- -42/ 58- -42/
.46 HYVO
23-39 74P 23-39 74P
58- -42/ 58- -42/
.46 HYVO
22-39 74P 22-39 74P
58- -40/ 58- -40/
.46 HYVO
22-40 74P 22-40 74P
58- -40/ 58- -40/
.46 HYVO