Polaris 2003 Pro X Service Manual page 16

GENERAL INFORMATION
MODEL: . . . . . . . . . .
MODEL NUMBER:
ENGINE MODEL:
CARBURETION
Type . . . . . . . . . . . . . . . . TM40 Mikuni
Main Jet . . . . . . . . . . . . 440
Pilot Jet . . . . . . . . . . . . . 45
Jet Needle . . . . . . . . . . . J8--9DGN5--57--3
Needle Jet . . . . . . . . . . . P-8
Cutaway . . . . . . . . . . . . 1.5
Fuel Screw . . . . . . . . . . 2.25 Turns
Valve Seat . . . . . . . . . . . 1.8
Fuel Octane (R+M/2) . 87 Non-Oxygenated
89 Oxygenated
Throttle Gap
Under Cutaway . . . . . . .0787 (2.0mm)
Starter Jet . . . . . . . . . . . 145
Pilot Air Jet . . . . . . . . . . N/A
Air Screw 1.25
Exhaust Valve Spring . Green/Yellow
CLUTCH
Type . . . . . . . . . . . . . . . . P-85
Belt . . . . . . . . . . . . . . . . . 3211080
Belt Width (Projected) 1.438 (36.52mm) .
Side Angle (Overall) . . 28
Outside Circumference 46.625
Center Distance . . . . . . 11.50
Shift Weights . . . . . . . . 10-62
Primary Spring . . . . . . . Black / Green
Secondary Spring . . . . Black/Red
Driven Helix . . . . . . . . . Team 62--42/.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 (8mm)
Crankcase Torque (10mm)
Flywheel Torque . . . . . . . . . . . . .
1.10
700 PRO X
. S03NX7CS
. . S2378- -7070PA7C
Altitude ltitude
Meters Meters
( (Feet)
Liquid Cooled Case Reed Twin
701cc
3.1889 (81mm)
2.6772 (68mm)
. . . 0.0047 - 0.0060 (0.12 - 0.15mm)
0.0060" (0.15mm)
3021307
N/A
. . . . . . . . .012mm
. . . . . . . 37cc
29.5 -- 30.5cc
8100 RPM
1400 RPM
. . . . . . 3500 RPM
. . . . . . . . 18-22 ft.lbs. (25-30 Nm)
. . . . 30-34 ft.lbs. (41-47 Nm)
. . . . . 20-24 ft.lbs. (28-33 Nm)
. . . 26-30 ft.lbs. (36-42 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- -600 480 460
(0- -2000)
#4
600- -1200
450 430
(2000- -4000)
#3
1200- -1800 1200 1800
420 420 400 400
(4000- -6000) ( 000 6000)
) #3
1800- -2400 400 400 380 380
(6000- -8000) (6000 8000)
#3 3
2400- -3000 370 3 0 350 350
(8000 10000) (8000- -10000)
#3 3
3000- -3700 340 3 0 330 330
(10000 12000) (10000- -12000)
#2 2
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
#3 #3 #3
410 400
#3 #3 #3
390 390 370 370
#3 #3 #2
360 360 340 340
#3 3 #2 2 #2 2
330 330 3 0 320
#2 2 #2 2 #2 2
3 0 310 290 90
#2 2 #2 2 #2 2
DRIVE
Shift Shift Clutch Clutch Clutch Clutch
Weight Spring Spring
Black / Black / Black / Black /
10-62 10 62
Green Red
Black / Black / Black / Black /
10 60 10-60
Green Red
Black / Black / Black / Black /
10-58 10 58
Green Red
Black / Black / Black / Black /
10 56 10-56
Green Red
. . . . . N/A
. . . . . . . N/A
. . . . . . . Mikuni
. . . . . . . . 2540102
. . . . 3021342
+30_to +50_F Above +50_F
-1 to +10 C -1_to +10_C Above +10_C Above +10 C
400 390
#3 #2
380 360
#2 #2
350 350 330 330
#2 #2
330 330 310 310
#2 2 #2 2
300 300 280 80
#2 2 #2 2
270 0 260 60
#2 2 #2 2
DRIVEN
Chaincase Chaincase
Driven Driven
Helix
Gearing
25- -41 76P 25- -41 76P
62- -42/ 62- -42/
.46 HYVO
25- -41 76P 25- -41 76P
62- -42/ 62- -42/
.46 HYVO
23-39 74P 23-39 74P
62- -40/ 62- -40/
.46 HYVO
23-39 74P 23-39 74P
62- -40/ 62- -40/
.46 HYVO