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2003 Pro X
Polaris 2003 Pro X User Manual
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REAR
SUSPENSION/
TRACK/T
RACTION
7.1
Pro
X
Rear
Suspen
sion
Impr
ovement
s
Improve
d
Front
T
orque
Arm
desi
gn
New
1
5/8”
“SNO
X”
Pattern
T
rack
H
W
alker
Evans
Racing
Sh
ocks
Enfocus
Software
-
Customer
Support
238
240
Table of Contents
Safety Labels and Instructions
3
General Information
6
Table of Contents
6
Break-In
7
Two-Cycle Engine Fuel / Oil Ratio Chart
7
PRO X Introduction
7
Trail Use Set up
8
Octane Jetting Chart
8
Publication Numbers
9
Specifications
10
Jetting Chart
10
440 PRO X Fan
10
Pro X
10
Pro
12
Pro
13
Pro
14
Conversion Charts
21
SAE Tap Drill Sizes
23
Metric Tap Drill Sizes
23
Glossary
24
Service
27
Tool List
28
Recommended Maintenance Products
29
Engine
31
Engine Torques
34
Spark Plugs
34
Formulas
36
Variable Exhaust System (V.E.S.)
38
V.E.S. Maintenance
39
V.E.S. Troubleshooting
39
Changing the Timing Curve
41
Engine Disassembly
42
Engine Assembly
49
Reed Valve Inspection
68
V.E.S. Removal
75
V.E.S. Disassembly, Cleaning, Inspection
76
V.E.S. Assembly
77
Variable Exhaust System Springs
78
Cylinder Service
79
Cylinder Honing
79
Cylinder Hone Selection
79
Honing to Oversize
79
Port Chamfering
80
Cleaning the Cylinder after Honing
80
Crankcase Inspection / Bearing Fit
80
Crankshaft Main Bearing Inspection
80
Connecting Rod (Big End) Bearing Inspection
81
Piston Pin / Needle Bearing Inspection
81
Connecting Rod Small End Inspection
81
Crankshaft Truing
82
Crankshaft Runout Inspection
82
Crankshaft Indexing
84
Exhaust Gas Tempurature
85
Piston Wash and Spark Plug Color
86
Cylinder Head Inspection
87
Cylinder Measurement
87
Piston Inspection/Measurement
88
Piston Ring Installed Gap
88
Oil Pump Operation and Troubleshooting
89
Oil Pump Bleeding
90
Oil Pump Adjustment - All Models
90
Oil Pump Drive Gear End Play Adjustment
90
Filling and Bleeding Procedure
92
440/500/600/700 Domestic Twins Bleeding Procedure
92
Cooling System View
93
Engine Troubleshooting
96
Fuel/Carburation
97
Jet Part Numbers
99
Pilot Jet Part Numbers
101
Throttle Valve Cutaway Part Numbers
101
Throttle Valve
101
Jet Needle Overview
102
Carburetor Exploded View
103
Fuel Delivery System - Typical
106
Typical Mikuni Starter System - Closed Throttle
107
Pilot System (0-3/8 Throttle)
108
Pilot Jet
108
Pilot Air Screw
108
Slide Cutaway (1/8-3/8 Throttle)
109
Jet Needle/Needle Jet (3/8-3/4 Throttle)
110
Throttle Opening Vs. Fuel Flow
110
Main System (3/4 to Full Throttle)
111
Main Jet
111
Jetting Guidelines
111
The Function of a Carburetor
112
Float System
112
Component Effect Vs Throttle Opening
113
Throttle Synchronization Procedure
114
Throttle Cable Synchronization (Throttle Gap)
114
Idle Gap Synchronization
114
Mikuni TM-38 / TM-40 Carburetor Service
115
Carburetor Removal, Disassembly, and Inspection
115
Carburetor Adjustments
120
Throttle Synchronization
120
Mikuni TMX Carburetor Service
122
Carburetor Removal, Disassembly, and Inspection (Typical VM Mikuni)
122
Mikuni TMX Service 3.24
122
Float Level Adjustment
124
Leak Testing Needle and Seat
124
Adjustments
125
Adjustments - Jet Needle and Float Level
126
Fine Tuning the Mikuni Carburetor
126
Adjustments - Choke
127
Fuel Pump - Operation
128
Fuel Pump Maintenance
128
Fuel System Troubleshooting
129
Clutching
131
Essential Drive Clutch Tools
133
Pro X Drive Clutch Puller Chart
133
Service Tools
133
Drive Clutch Weight Identification - Actual Size
134
Drive Clutch Spring Rate Chart
138
Drive Clutch Spring Data
139
Driven Clutch Springs (Polaris Clutch)
140
Effects of Driven Clutch Helix Ramp
142
Helix Angles and Effects (Polaris Clutch)
143
Team Clutch Info
144
Driven Ramp
144
Driven Springs
144
High Performance Roller Helix Explained
145
P-85 Drive Clutch Exploded View
146
P-85 Driven Clutch Exploded View
147
Team Roller Clutch Exploded View
148
Drive System Operation
149
Relationship between Drive Clutch Weights and Spring
149
Clutch Maintenance
151
Spider Indexing
152
Clutch Removal
153
Clutch Identification
153
Clutch Disassembly and Inspection
154
Spider Roller Removal
156
Roller Installation
156
Spider Button Shimming
157
Drive Clutch Assembly
159
Drive Clutch Installation
160
Driven Clutch Removal
162
Driven Clutch Disassembly
163
Driven Clutch Assembly
165
Helix Angles and Effects
166
Helix Ramps
166
Driven Clutch Installation
168
High Performance Roller Clutch Maintenance/Adjustment
169
General Belt Selection Guidelines
171
Drive Belt 4.39
171
Drive Belt Inspection
172
Belt Wear / Burn Diagnosis
172
Belt Deflection
173
Measuring Belt Deflection
173
Adjusting Belt Deflection
174
Adjusting Belt Deflection on the High Performance Roller
175
Belt Removal on High Performance Roller
175
Clutch Offset Inspection (ALL)
176
Clutch Offset Adjustment
176
Clutch Alignment Inspection
177
Clutch Alignment Adjustment
177
Torque Stop Adjustment
177
Belt to Sheave Clearance Inspection
178
Belt to Sheave Clearance Adjustment
178
Twin Wide Roller Spider Rebuild Kit Installation
179
Clutch Troubleshooting
181
Chassis/Final Drive
183
440 Pro X Bulkhead / Tunnel and Chassis Changes
185
HYVO Sprocket Part Numbers
188
Optional Tracks/ ISR Optional Tracks
189
Pro X Tunnels
190
Hydraulic Brake System Operation
191
Compensating Port
191
Brake Bleeding - Fluid Change
192
Brake Bleeding - System Rebuild
193
Brake System
194
Wilwoodt Master Cylinder
194
Hayest
194
Wilwood Master Cylinder Removal and Inspection
195
Liquid Cooled Brake Pad Replacement
198
Rear Suspension Removal
199
Chaincase Removal
200
Chaincase Bearing Removal
201
Jackshaft Removal
202
Driveshaft Removal
202
Chaincase Bearing Assembly
203
Jackshaft Installation
203
Driveshaft Installation
205
Track Installation
206
Final Assembly
207
Front Suspension
211
Spring Data
214
Maximum Spring Preload Matrix
216
Optional IFS Springs
217
Torsion Bars Kits
218
Adjustable Torsion Bar Assembly
218
Pro X Radius Rods
218
Front Suspension Setup and Adjustments
219
Spring Rate
219
Set up and Adjustments
219
Springs
220
Dual Rate Springs
221
Torque Specifications (Steering/Front Suspension)
222
Torque Application List
222
Steering Inspection
223
Alignment Bar Specifications
223
Camber Definition - All IFS
224
Radius Rod and Tie Rod End Torque Procedure
224
Rod End Engagement Guidelines - All IFS
224
Steering Alignment Specifications
225
Camber
225
Spindle Centering / Set up Width / Camber Adjustment
226
Camber Adjustment 6.15
227
Camber Inspection
228
Camber - Acceptable Range
228
Handlebar Centering Adjustment
229
Toe Adjustment
230
Steering Arm Orientation
231
Carbide to Ski Placement
231
Shocks
232
Rear Suspension
237
Rear Suspension Improvements
239
Suspension Torque Specifications
240
Rear Suspension Specifications
240
Rear Only Xtra Travel Arm Orientation
240
Rear Suspension Operation
241
Weight Transfer
241
Rear Suspension Tuning
243
Shock Tuning
243
Rebuildable Shocks
243
Shock Valving
244
Shock Valving Arrangement
246
Shock Specifications
247
Rear Shock Maintenance
254
Valve Stack Maintenance
255
Shock Assembly
255
Filling, Bleeding, & Charging (Shocks)
255
Racing Shocks Valve Part Numbers
257
Ryde FX Shock Maintenance
258
Ryde FX Valve Washer Part Numbers
266
Suspension Lubrication
267
Rear Suspension Components - Pro X
268
Rear Suspension Exploded View - Pro X Style
269
Track Tension
270
Hi-Fax Replacement
271
XTRA Lite Wide Hi-Fax
272
Hi-Fax Removal
272
Rubber Track Clip Replacement
272
Traction
273
Stud Installation
274
T-Nut Studs
274
Push through Studs
274
Electrical
277
Engine Electrical
279
Ignition Timing
279
Dial Indicating the Timing Marks
279
Conversion Chart - Degrees to Piston Position - B.T.D.C.
280
Twin Cylinder Fan CDI Ignition - Exploded View - Timing
281
Exploded View - Timing
282
CDI Ignition Timing
284
Stator Diameter
285
Ignition System Testing
285
Multimeter Usage
286
Short Circuit Current (AC Amp Test)
288
Regulated Voltage
288
Alternators
289
Polaris Snowmobiles
289
Tachometers
289
Exhaust System Temperature Sender
290
Temp Sender
290
Headlight Bulb Filament Continuity Test
291
Hi/Lo Beam Switch Testing
291
Seat Harness Troubleshooting
291
Ignition Switch Testing (Non-Electric Start)
292
Ignition Switch Testing (Electric Start Models)
292
Coolant High Temperature Indicator Testing
293
Temp Light Temperature Sensor Test
293
Polaris Dragont Ignition Operation
293
Speed Control Assurance Operation
294
Speed Control Assurance Adjustment
294
Speed Control Assurance Testing
295
Speed Control Assurance Replacement
295
TPS (Throttle Position Sensor)
296
TPS Testing
296
TPS Adjustment
298
Electical - Troubleshooting
300
No Spark
300
Incorrect Advance/Retard
300
Wiring Diagram
301
Index
305
5
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Polaris 2003 Pro X Specifications
General
Brand
Polaris
Model
2003 Pro X
Category
Offroad Vehicle
Language
English
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