Carburetion; Jetting Chart; Clutch Chart - Polaris INDY TRAIL RMK Service Manual

GENERAL INFORMATION
INDY 500 SKS EUROPEAN
MODEL: . . . . . . . . . .
MODEL NUMBER: . E02SS5AE
ENGINE MODEL: . . S2209- -5044PL5A

CARBURETION

Type . . . . . . . . . . . . . . . . TM 38 Mikuni
Main Jet . . . . . . . . . . . . 370
Pilot Jet . . . . . . . . . . . . . 45
Jet Needle . . . . . . . . . . . 9FH4--57/3
Needle Jet . . . . . . . . . . . P-6
Cutaway . . . . . . . . . . . . 1.5
Fuel Mixture Screw . . . 2 Turns
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenat ed
89 Oxygenated
Throttle Gap
Under Cutaway . . . . . . 0.098² (2.5mm)
Starter Jet . . . . . . . . . . . 155
Pilot Air Jet . . . . . . . . . . 1.0
CLUTCH
Type . . . . . . . . . . . . . . . . P 85
Belt . . . . . . . . . . . . . . . . . 3211074
Belt Width (Projected) 1.438² .
Side Angle (Overall) . . 28°
Outside Circumference 47.625²
Center Distance . . . . . . 12.00²
Shift Weights . . . . . . . . 10-56 Bushed
Primary Spring . . . . . . . Dark Blue / White
Secondary Spring . . . . Silver
Driven Helix . . . . . . . . . R32 #2
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±300
Cylinder Head Torque . . . . . . . .
Cylinder Base Nut Torque
Crankcase Torque (8mm)
Crankcase Torque (10mm)
Flywheel Torque . . . . . . . . . . . . .
1.14
Altitude Altitude
Meters Meters
( (Feet) )
Liquid Cooled Case Reed Twin
500cc
2.776²² (70.5mm)
2.520²² (64mm)
. . . 0.0045² - 0.0063² (0.11 - 0.16mm)
N/A
3021038
N/A
0.012² - 0.018² (.30 - .46mm)
. . . . . . . 27.5±.50cc
25cc
8000 RPM
1500 RPM
. . . . . . 4200 RPM
20-24 ft.lbs. (28-33Nm)
. . . . 30-34 ft.lbs. (41-47 Nm)
. . . . . 20-24 ft.lbs. (28-33 Nm)
. . . N/A
90 ft.lbs. (124 Nm)

JETTING CHART

AMBIENT TEMPERATURE
Below -30°F
-30_ to - -10_F
Below -34°C
Below 34 C -34_to -23_C -34 to -23 C
390 380
0- -600
(0- -2000)
#3 #3
600- -1200 370 360
(2000- -4000)
#3 #3
1200- -1800 1200 1800 350 350 330 330
( 000 6000) (4000- -6000)
#3 #3
1800- -2400 330 330 310 3 0
(6000 8000) (6000- -8000)
#3 #3
#3 #3
2400- -3000 300 300 290 90
(8000 10000) (8000- -10000)
#3 #3 #3 #3
280 80 270 0
3000- -3700
(10000- -12000) (10000 12000)
#3 #3 #2 #2
XXX
#X
- # refers to the clip position from top of jet needle.

CLUTCH CHART

DRIVE
Altitude Altitude
Shift Shift
Weight
Meters Meters
0-900 0-900 10-56 10-56
(Feet)
(0-3000)
Bushed
900-1800 900-1800 10-AL 10-AL
(3000-6000)
Bushed
1800-2700 1800-2700 10 10
(6000-9000)
Bushed
2700-3700 2700-3700 10M5 10M5
(9000-12000)
Bushed
- Production Setting
Fuel Pump Manuf.
Fuel Pump Mark
Oil Pump Manuf.
Oil Pump Mark
Cylinder Head Mark
- -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
360 350 330
#3 #3 #3
340 330 310
#3 #3 #3
320 320 300 300 290 290
#3 #3 #2
300 300 290 90 3 0 370
#3 #2
#3 #2 #2 #2
280 80 260 60 250 50
#2 #2 #2 #2 #2 #2
250 50 240 0 220 0
#2 #2 #2 #2 #2 #2
DRIVEN
Chaincase Chaincase
Clutch Clutch Clutch Clutch Driven Driven
Spring Spring Helix
18-41-68P 18-41-68P
Dark Blue / Dark Blue / R32 R32
Silver Silver
White #2
18-41-68P 18-41-68P
Almond / Almond / R32 R32
Silver Silver
Round #2
18-41-68P 18-41-68P
Almond / Almond / R32 R32
Silver Silver
Round #2
18-41-68P 18-41-68P
Almond / Almond / R32 R32
Silver Silver
Round #2
. . . . . N/A
. . . . . . . N/A
. . . . . . . Mikuni
. . . . . . . . 2540051
. . . . 3021048
Above +50_F
Above +10 C Above +10_C
320
#3
300
#2
280 280
#2
250 50
#2 #2
230 30
#1 #1
210 0
#2 #2
Gearing
HYVO
HYVO
HYVO
HYVO