Table Of Contents - Polaris 2003 Pro X Service Manual

Table of Contents

Safety Labels And Instructions3
General Information6
Table Of Contents6
Break-In7
Two-Cycle Engine Fuel / Oil Ratio Chart7
Pro X Introduction7
Trail Use Set Up8
Octane Jetting Chart8
Publication Numbers9
Specifications10
Jetting Chart10
440 Pro X Fan10
Pro X10
Pro12
Conversion Charts21
Sae Tap Drill Sizes23
Metric Tap Drill Sizes23
Glossary24
Service27
Tool List28
Recommended Maintenance Products29
Engine31
Engine Torques34
Spark Plugs34
Formulas36
Variable Exhaust System (V.e.s.)38
V.e.s. Maintenance39
V.e.s. Troubleshooting39
Changing The Timing Curve41
Engine Disassembly42
Engine Assembly49
Reed Valve Inspection68
V.e.s. Removal75
V.e.s. Disassembly, Cleaning, Inspection76
V.e.s. Assembly77
Variable Exhaust System Springs78
Cylinder Service79
Cylinder Honing79
Cylinder Hone Selection79
Honing To Oversize79
Port Chamfering80
Cleaning The Cylinder After Honing80
Crankcase Inspection / Bearing Fit80
Crankshaft Main Bearing Inspection80
Connecting Rod (Big End) Bearing Inspection81
Piston Pin / Needle Bearing Inspection81
Connecting Rod Small End Inspection81
Crankshaft Truing82
Crankshaft Runout Inspection82
Crankshaft Indexing84
Exhaust Gas Tempurature85
Piston Wash And Spark Plug Color86
Cylinder Head Inspection87
Cylinder Measurement87
Piston Inspection/Measurement88
Piston Ring Installed Gap88
Oil Pump Operation And Troubleshooting89
Oil Pump Bleeding90
Oil Pump Adjustment - All Models90
Oil Pump Drive Gear End Play Adjustment90
Filling And Bleeding Procedure92
440/500/600/700 Domestic Twins Bleeding Procedure92
Cooling System View93
Engine Troubleshooting96
Fuel/Carburation97
Jet Part Numbers99
Pilot Jet Part Numbers101
Throttle Valve Cutaway Part Numbers101
Throttle Valve101
Jet Needle Overview102
Carburetor Exploded View103
Fuel Delivery System - Typical106
Typical Mikuni Starter System - Closed Throttle107
Pilot System (0-3/8 Throttle)108
Pilot Jet108
Pilot Air Screw108
Slide Cutaway (1/8-3/8 Throttle)109
Jet Needle/Needle Jet (3/8-3/4 Throttle)110
Throttle Opening Vs. Fuel Flow110
Main System (3/4 To Full Throttle)111
Main Jet111
Jetting Guidelines111
The Function Of A Carburetor112
Float System112
Component Effect Vs Throttle Opening113
Throttle Synchronization Procedure114
Throttle Cable Synchronization (Throttle Gap)114
Idle Gap Synchronization114
Mikuni Tm-38 / Tm-40 Carburetor Service115
Carburetor Removal, Disassembly, And Inspection115
Carburetor Adjustments120
Throttle Synchronization120
Mikuni Tmx Carburetor Service122
Carburetor Removal, Disassembly, And Inspection (Typical Vm Mikuni)122
Mikuni Tmx Service 3.24122
Float Level Adjustment124
Leak Testing Needle And Seat124
Adjustments125
Adjustments - Jet Needle And Float Level126
Fine Tuning The Mikuni Carburetor126
Adjustments - Choke127
Fuel Pump - Operation128
Fuel Pump Maintenance128
Fuel System Troubleshooting129
Clutching131
Essential Drive Clutch Tools133
Pro X Drive Clutch Puller Chart133
Service Tools133
Drive Clutch Weight Identification - Actual Size134
Drive Clutch Spring Rate Chart138
Drive Clutch Spring Data139
Driven Clutch Springs (Polaris Clutch)140
Effects Of Driven Clutch Helix Ramp142
Helix Angles And Effects (Polaris Clutch)143
Team Clutch Info144
Driven Ramp144
Driven Springs144
High Performance Roller Helix Explained145
P-85 Drive Clutch Exploded View146
P-85 Driven Clutch Exploded View147
Team Roller Clutch Exploded View148
Drive System Operation149
Relationship Between Drive Clutch Weights And Spring149
Clutch Maintenance151
Spider Indexing152
Clutch Removal153
Clutch Identification153
Clutch Disassembly And Inspection154
Spider Roller Removal156
Roller Installation156
Spider Button Shimming157
Drive Clutch Assembly159
Drive Clutch Installation160
Driven Clutch Removal162
Driven Clutch Disassembly163
Driven Clutch Assembly165
Helix Angles And Effects166
Helix Ramps166
Driven Clutch Installation168
High Performance Roller Clutch Maintenance/Adjustment169
General Belt Selection Guidelines171
Drive Belt 4.39171
Drive Belt Inspection172
Belt Wear / Burn Diagnosis172
Belt Deflection173
Measuring Belt Deflection173
Adjusting Belt Deflection174
Adjusting Belt Deflection On The High Performance Roller175
Belt Removal On High Performance Roller175
Clutch Offset Inspection (All)176
Clutch Offset Adjustment176
Clutch Alignment Inspection177
Clutch Alignment Adjustment177
Torque Stop Adjustment177
Belt To Sheave Clearance Inspection178
Belt To Sheave Clearance Adjustment178
Twin Wide Roller Spider Rebuild Kit Installation179
Clutch Troubleshooting181
Chassis/Final Drive183
440 Pro X Bulkhead / Tunnel And Chassis Changes185
Hyvo Sprocket Part Numbers188
Optional Tracks/ Isr Optional Tracks189
Pro X Tunnels190
Hydraulic Brake System Operation191
Compensating Port191
Brake Bleeding - Fluid Change192
Brake Bleeding - System Rebuild193
Brake System194
Wilwoodt Master Cylinder194
Hayest194
Wilwood Master Cylinder Removal And Inspection195
Liquid Cooled Brake Pad Replacement198
Rear Suspension Removal199
Chaincase Removal200
Chaincase Bearing Removal201
Jackshaft Removal202
Driveshaft Removal202
Chaincase Bearing Assembly203
Jackshaft Installation203
Driveshaft Installation205
Track Installation206
Final Assembly207
Front Suspension211
Spring Data214
Maximum Spring Preload Matrix216
Optional Ifs Springs217
Torsion Bars Kits218
Adjustable Torsion Bar Assembly218
Pro X Radius Rods218
Front Suspension Setup And Adjustments219
Spring Rate219
Set Up And Adjustments219
Springs220
Dual Rate Springs221
Torque Specifications (Steering/Front Suspension)222
Torque Application List222
Steering Inspection223
Alignment Bar Specifications223
Camber Definition - All Ifs224
Radius Rod And Tie Rod End Torque Procedure224
Rod End Engagement Guidelines - All Ifs224
Steering Alignment Specifications225
Camber225
Spindle Centering / Set Up Width / Camber Adjustment226
Camber Adjustment 6.15227
Camber Inspection228
Camber - Acceptable Range228
Handlebar Centering Adjustment229
Toe Adjustment230
Steering Arm Orientation231
Carbide To Ski Placement231
Shocks232
Rear Suspension237
Rear Suspension Improvements239
Suspension Torque Specifications240
Rear Suspension Specifications240
Rear Only Xtra Travel Arm Orientation240
Rear Suspension Operation241
Weight Transfer241
Rear Suspension Tuning243
Shock Tuning243
Rebuildable Shocks243
Shock Valving244
Shock Valving Arrangement246
Shock Specifications247
Rear Shock Maintenance254
Valve Stack Maintenance255
Shock Assembly255
Filling, Bleeding, & Charging (Shocks)255
Racing Shocks Valve Part Numbers257
Ryde Fx Shock Maintenance258
Ryde Fx Valve Washer Part Numbers266
Suspension Lubrication267
Rear Suspension Components - Pro X268
Rear Suspension Exploded View - Pro X Style269
Track Tension270
Hi-Fax Replacement271
Xtra Lite Wide Hi-Fax272
Hi-Fax Removal272
Rubber Track Clip Replacement272
Traction273
Stud Installation274
T-Nut Studs274
Push Through Studs274
Electrical277
Engine Electrical279
Ignition Timing279
Dial Indicating The Timing Marks279
Conversion Chart - Degrees To Piston Position - B.t.d.c.280
Twin Cylinder Fan Cdi Ignition - Exploded View - Timing281
Exploded View - Timing282
Cdi Ignition Timing284
Stator Diameter285
Ignition System Testing285
Multimeter Usage286
Short Circuit Current (Ac Amp Test)288
Regulated Voltage288
Alternators289
Polaris Snowmobiles289
Tachometers289
Exhaust System Temperature Sender290
Temp Sender290
Headlight Bulb Filament Continuity Test291
Hi/Lo Beam Switch Testing291
Seat Harness Troubleshooting291
Ignition Switch Testing (Non-Electric Start)292
Ignition Switch Testing (Electric Start Models)292
Coolant High Temperature Indicator Testing293
Temp Light Temperature Sensor Test293
Polaris Dragont Ignition Operation293
Speed Control Assurance Operation294
Speed Control Assurance Adjustment294
Speed Control Assurance Testing295
Speed Control Assurance Replacement295
Tps (Throttle Position Sensor)296
Tps Testing296
Tps Adjustment298
Electical - Troubleshooting300
No Spark300
Incorrect Advance/Retard300
Wiring Diagram301
Index305