2001 HIGH PERFORMANCE SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary importance. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 2001 Polaris snowmobiles. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340.
2001 High Performance Snowmobile Service Manual (PN 9916690) Copyright 2000 Polaris Sales Inc.
Printed in U.S.A.
CHAPTER INDEX CHAPTER 1 . . . . . . . . . . . . . . . . General Information CHAPTER 2 . . . . . . . . . . . . . . . . Engines CHAPTER 3 . . . . . . . . . . . . . . . . Fuel / Carburetion CHAPTER 4 . . . . . . . . . . . . . . . . Drive / Driven Clutches CHAPTER 5 . . . . . . . . . . . . . . . . Chassis, Brakes and Final Drive CHAPTER 6 . . . . . . . . . . . . . . . . Front Suspensions CHAPTER 7 . . . . . . . . . . . . . . . . Rear Suspensions CHAPTER 8 . . . . . . . . . . . . . . . . Electrical/Wiring Diagrams
CHAPTER 1 GENERAL INFORMATION
High Performance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Break--In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Race Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Publication numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, XCF SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 440 EDGE Pro X . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 600 EDGE Pro X . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 500 XC EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 500 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 600 XC SP, EDGE X . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 700 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 800 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 800 XCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 500 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 600 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 700 RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications, 800 RMK, S.C. SP . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Set Up Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1--1.2 1.3 1.4 1.5--1.6 1.8--1.9 1.10--1.1 1.12--1.13 1.14--1.15 1.16-1.17 1.18--1.19 1.20--1.21 1.22--1.23 1.24--1.25 1.26--1.27 1.28--1.29 1.30--1.31 1.32--1.33 1.34 1.35 1.36 1.37 1.38--1.40 1.41 1.42--1.49
GENERAL INFORMATION
PART
DESCRIPTION
NUMBER
PART
DESCRIPTION
Fox Shocks NUMBER 2900153
REMOTE RESERVOIR REAR TRACK (RACE)
2900152
REMOTE RESERVOIR REAR TRACK (TRAIL)
2900049
XTRA LITE COMPETITION PACKAGE
2900068
TORSION BAR,9/16”, 2000--01 EDGE
2900069
TORSION BAR,5/8”, 2000--01 EDGE
2900071
Lightweight Sway Bar Kit Tubular (5/8 EDGE 00--01)
2900070
Lightweight Sway Bar Kit Tubular (5/8 RMK 00--01)
2900183
Lighweight Sway Bar Kit,5/8” Tubular, 01 EDGE Racer
2900184
Lightweight Sway Bar Kit Tubular, 9/16”, (01 EDGE Racer)
2900156
KIT--IDLER WHEEL,4TH
Clutch Components 2900178
ROLLER DRIVEN CLUTCH
Roller Clutch Components 2900169
HELIX,DRIVEN, 34--DEG,ROLLER
2900177
HELIX,DRIVEN, R3,ROLLER
2900172
HELIX,DRIVEN, R12, ROLLER
2900173
HELIX,DRIVEN, R11, ROLLER
2900176
HELIX,DRIVEN, R4, ROLLER
2900170
HELIX,DRIVEN, 36--DEG, ROLLER
2900174
HELIX,DRIVEN, R8, ROLLER
2900171
HELIX,DRIVEN, R32, ROLLER
2900175
HELIX,DRIVEN, R5, ROLLER
5521587--309
EDGE EXTRA WIDE RAIL SLIDERS (01 EDGE Racer)
Button Clutch Components 2900034
Ramp, driven, 40--36 Combo
2900035
Ramp, driven, R1, 40--32
2900036
Ramp, driven, 42--32
2900037
Ramp, driven, R3, 45--32
2900038
Ramp, driven, R4, 50--32
2900039
Ramp, driven, R5, 40--34
2900040
Ramp, driven, R6, 42--34
2900041
Ramp, driven, R7, 45--34
2900042
Ramp, driven, R8, 50--34
2900043
Ramp, driven, R9, 40--36
2900044
Ramp, driven, R10, 42--36
2900045
Ramp, driven, R11, 45--36
2900046
Ramp, driven, R32, 50--34
5521556--309
2900067
EDGE EXTRA WIDE RAIL SLIDERS (00--01 EDGE)
TIE DOWN KIT,HOOD Hood/Seat
2900047
Ramp, driven, R12, 50--36
2900048
Ramp, driven, 42 / 36 / 34
2900026
WEIGHT,SHIFT,MATCHED,10--60
2900027
WEIGHT,SHIFT,MATCHED,10--56
2900028
WEIGHT,SHIFT,MATCHED,10--54
2900029
WEIGHT,SHIFT,MATCHED,10--58
2900129--293
Lightweight Composite Hood EDGE Racing (Red)
2900128--070
Lightweight Composite Hood RMK (Black)
2900128--293
Lightweight Composite Hood RMK (Red)
2900128--246
Lightweight Composite Hood RMK (Rigel Blue)
2900124
Lightweight Seat RMK
2900181
Lightweight Seat EDGE
Torsion Spring Kits (90 Weights
Belts 3211086
Belt, Close Tolerance Standard Compound, EDGE
3211087
Belt, Close Tolerance CVT Compound, EDGE Engine Kits
2900151
HIGH ALTITUDE HEAD (2000 800 RMK)
2900127
Electric E.V. Kit (500 E.V. Engines)
2900126
Electric E.V. Kit (600 E.V. Engines)
2900063
TORSION SPRING KIT .347, 90 Deg. Square
2900064
TORSION SPRING KIT .359, 90 Deg. Square
2900065
TORSION SPRING KIT .375, 90 Deg. Square
2900066
TORSION SPRING KIT .405, 90 Deg. Square
2900095
TORSION SPRING KIT .347, 77 Deg. Square
2900096
TORSION SPRING KIT .359, 77 Deg. Square
2900097
TORSION SPRING KIT .375, 77 Deg. Square
2900098
TORSION SPRING KIT .405, 77 Deg. Square
1.1
GENERAL INFORMATION 2900002
18 Tooth HYVO, Cut Metal Gear
2900003
19 Tooth HYVO, Cut Metal Gear
2900004
20 Tooth HYVO, Cut Metal Gear
2900005
21 Tooth HYVO, Cut Metal Gear
2900006
22 Tooth HYVO, Cut Metal Gear
2900007
23 Tooth HYVO, Cut Metal Gear
2900008
24 Tooth HYVO, Cut Metal Gear
2900009
25 Tooth HYVO, Cut Metal Gear
2900010
37 Tooth HYVO, Cut Metal Gear
2900011
38 Tooth HYVO, Cut Metal Gear
2900012
39 Tooth HYVO, Cut Metal Gear
2900013
40 Tooth HYVO, Cut Metal Gear
2900014
41 Tooth HYVO, Cut Metal Gear
2900015
42 Tooth HYVO, Cut Metal Gear
2900016
43 Tooth HYVO, Cut Metal Gear
2900138
43 Tooth, Lightweight Cut Metal Gear, HYVO
2900139
42 Tooth, Lightweight Cut Metal Gear, HYVO
2900140
41 Tooth, Lightweight Cut Metal Gear, HYVO
2900141
40 Tooth, Lightweight Cut Metal Gear, HYVO
2900142
39 Tooth, Lightweight Cut Metal Gear, HYVO
2900143
38 Tooth, Lightweight Cut Metal Gear, HYVO
2900144
37 Tooth, Lightweight Cut Metal Gear, HYVO
2900025
Lightweight Jackshaft Kit
3221108
Chain HYVO, 76 PITCH
3221109
Chain HYVO, 74 PITCH
3221110
Chain HYVO, 72 PITCH
3221112
Chain HYVO, 68 PITCH
3221113
Chain HYVO, 66 PITCH
3221114
Chain HYVO, 64 PITCH
3221115
Chain HYVO, 70 PITCH
2900180
MOTOR--MOUNT,KIT,AGGR,TRAIL,65 EDGE
2900179
MOTOR--MOUNT,KIT, DRAG,65 EDGE
2900020
MOTOR--MOUNT,KIT,AGGR,TRAIL,70D
2900021
MOTOR--MOUNT,KIT,DRAG,90D
2900022
MOTOR--MOUNT,KIT,DRAG,90D
2900023
MOTOR--MOUNT,KIT,AGGR,TRAIL,70D
2900024
MOTOR--MOUNT,KIT,DRAG,90D
2900019
TRACK,121”X1.5 --NOTCHED
2900018
TRACK,121”X--1.75 --NOTCHED
HYVO Chain
Motor Mounts
Tracks
1.2
2900017
TRACK,121X2” NOTCHED
5411825
TRACK--121”X15”X1”MOD LIGHTNING
5411963
TRACK--121X1.25 SHOCKWAVE
5411994
TRACK--121X15X1,SHOCKWAVE
5411995
TRACK--144”X2” Series 3 (Hard Lug)
GENERAL INFORMATION Polaris’ new 440 Edge Pro X and XCF SP edge models have been designed and tested to endure the toughest of all races. Many hours of testing have gone into development, and engineering has decided to use a predetermined weight rider and snow cross racing for stock setup. After uncrating your machine, be sure to test ride so setup can be determined for your riding style and characteristics. The following are setup tips for your brand new 440 Edge Pro X or XCF SP.
1. Stock suspension setup for the 2001 440/600 Pro X and XCF SP is geared to a 170 lb (77.18 kg) pro rider. 2. Stock carburetion, clutching and gearing is for 0-3000 ft. (0-900 m). 3. In this manual, there are numerous optional springs, optional carburetor jets, optional clutch weights, and optional gears to suit your riding preference and location. When changing to optional parts, always test what you have done. Do not be afraid to experiment. 4. Be sure to use good quality studs and a pattern to maximize your traction and safety.
Break-in The new 440/600 Edge Pro X and XCF SP are high performance snowmobiles, and break-in is a vital step to ensure the performance of your machine will be at its peak. 1. 2. 3. 4. 5. 6.
Always break-in any new part for 50-75 miles before using it for racing. Clutch springs and belts need to be broken in to reach their peak in performance. On the 440 Edge Pro X, always use the correct type of fuel for the timing system you are using. Always use the recommended Polaris oil for your snowmobile. Always break-in a new or rebuilt engine to ensure durability. Maintain your exhaust valves frequently to ensure they are operating to their fullest capability.
440 Jetting for Temperature and Altitude
1.3
GENERAL GENERAL INFORMATION INFORMATION South Side Race Support: Contact: Bruce Gaspardi 546 Curran Hwy. North Adams, MA 01247 Phone: (413) 664-7111 Racing: Cross country, Snowcross Service Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, Woody’s traction products, clutch disassembly tools mounted in trailer, Hot Seat clutch parts, OEM clutch parts, NGK spark plugs, miscellaneous hardware. Wahl Brothers Racing: Contact: Dave Hwy 11 West Greenbush, MN 56726 Phone: (218) 782-2295 Racing: All Service Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, traction products, clutch disassembly, miscellaneous hardware. Karkoulas Racing: Contact: Troy Karkoulas S2225 Scugog Brock Town Line Sunderland ON Canada L0C 1H0 Phone: (705) 357--1226 Racing: All
Polaris Racing 10303 Calumet Ave. Suite # 3 Mosinee, WI 54455 Phone: (715) 355--5157 Fax: (715) 355--8797
1.4
GENERAL INFORMATION 2001 Publication Numbers Model
Model No.
Owner’s Manual Supplement
Parts Manual
Parts Microfiche
XCF
S01NX4FS
9916161
9916162
9916163
440 Edge Pro X
S01NX4CS
9916166
9916167
9916168
600 Edge Pro X
S01NX6ES
9916884
9916885
9916886
500 XC SP
S01NP5CS
9915889
9916040
9916041
600 XC SP / X
S01NP6ES
9915623
9916153
9916154
700 XC SP
S01NP7AS
9915929
9916090
9916091
800 XC SP
S01NP8BS
9915925
9916110
9916111
600 RMK 136
S01SR6DS
9916022
9916023
9916024
700 RMK 136
S01SR7AS
9916027
9916028
9916029
800 RMK 144, 151
S01SM8BS
9916143, 9916148
9916144
9916145
800 XCR
S01SB8AS
9916067
9916068
9916069
2000 Publication Numbers Model
Model No.
Owner’s Manual Supplement
Parts Manual
Parts Microfiche
XCF XC SP
S00NX4FS
9915615
9915616
9915617
440 XC SP
S00NX4CS
9915372
9915402
9915430
500 XC SP 45th Anniversary
S00SP5CS
9915373
9915403
9915431
600 XC SP
S00SP6ES
9915374
9915404
9915432
700 XC SP
S00SP7AS
9915377
9915407
9915435
600 RMK
S00SR6DS
9915382
9915412
9915440
700 RMK
S00SR7AS(A)
9915380
9915410
9915438
800 RMK
S00SR8BS
9915381
9915411
9915439
800 XCR
S00SB8AS
9915371
9915401
9915429
2001 Snowmobile Owner’s Manual (All) - 9915622 2000 Snowmobile Owner’s Manual (All) - 9915247 2000 High Performance Manual - 9915985
1.5
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GENERAL GENERAL INFORMATION INFORMATION Service Manuals 120 XC SP
2001
9916684
Trail Sport 340 DLX, Indy 500 EDGE, SuperSport EDGE
2001
9916685
Two-Up / Touring Wide Trak LX, 340 Touring, Sport Touring, Sport Touring ES, 500 Classic Touring, 600 Classic Touring
2001
9916686
Trail Luxury 500 Classic, 600 Classic, 700 Classic, 800 LE
2001
9916687
Deep Snow 700 SKS, Trail RMK, 500/600/700/800 RMK, 800 RMK Snowcheck Special
2001
9916688
Performance 500 XC, 500/600/700/800 XC SP, 600 EDGE X, 800 XCR
2001
9916689
High Performance (Race) 440 XCF SP, 440/600 Edge Pro X, 500/600/700/800 XC SP, 600/700/800 RMK, 800 XCR
2001
9916690
Wallcharts
2001
9916692
2000 Snow Complete Set w/wallcharts (all models except race)
2000
9915986
Fan Cooled Models
2000
9915980
Mid Range Liquid Cooled (500s, 600 triple)
2000
9915981
Performance Liquids (600 twins,700s, 800s)
2000
9915982
120 XCR
2000
9915983
High Performance (Race)
2000
9915985
Wall Chart Packet only
2000
9915984
1.6
GENERAL INFORMATION
2001 Specifications 440 XCF SP 440 Edge Pro X 600 Edge Pro X 500 XC Edge 500 XC SP Edge 600 XC SP, X Edge 700 XC SP Edge 800 XC SP Edge 500 RMK 600 RMK 700 RMK 800 RMK, S.C. Special
1.7
GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . XCF SP MODEL NUMBER: . S01NX4FS ENGINE MODEL: . . EC45PM022
JETTING CHART AMBIENT TEMPERATURE
Altitude
CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Air Screw . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) .
VM34AL Mikuni 340 PTO/330 MAG 45 6DHK06--03 Q-2(286) 3.0 1.0 Turns 1.5 Viton 87 Non-Oxygenated or 89 Oxygenated
Throttle Gap Under Cutaway . . . . . . .244〉 -(6.2mm) Idle Sync Gap Under Cutaway . . . . . . .218〉 - (5.54mm)
Meters (Feet)
Below -20F -20 F Below -29C
-20 to +10_F -20_ +10 F -29_to -12_C
+10 to +40_F +10_to +40 F -12_ to +5_C
Above +40_F +40 F Above 5_C
0-900 (0-3000)
PTO 360 MAG 350 #3
PTO 340 MAG 330 #3
PTO 320 MAG 310 #3
PTO 300 MAG 290 #3
900-1800 (3000-6000)
PTO 320 MAG 310 #3
PTO 310 MAG 300 #3
PTO 290 MAG 280 #3
PTO 270 MAG 260 #2
1800-2700 (6000-9000)
PTO 290 MAG 280 #3
PTO 270 MAG 260 #3
PTO 260 MAG 250 #2
PTO 240 MAG 230 #2
2700-3700 (9000-12000)
PTO 260 MAG 250 #3
PTO 250 MAG 240 #2
PTO 230 MAG 220 #2
PTO 220 MAG 210 #2
XXX #X - # refers to the clip position from top of jet needle. - Production Setting
CLUTCH CHART DRIVE
CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .
Altitude
P-85 3211078 1 7/16〉 28 56 5/8〉 11.50〉 10-54 Almond Red Silver/Blue R5 #2
Meters (Feet)
Clutch Spring
Clutch Spring
Driven Helix
Chaincase Gearing
0-900 (0-3000)
10-54 Bushed
Almond/ Red
Silver Blue
R5 #-2
22--43 P HYVO
900-1800 (3000-6000)
10-54 Bushed
Almond/ Red
Silver Blue
R5 #-2
22--43 74 P HYVO
1800-2700 (6000-9000)
10
Almond/ Red
Silver Blue
R5 #-2
22--43 74 P HYVO
2700-3700 (9000-12000)
10
Almond/ Red
Silver Blue
R5 #-2
22--43 74 P HYVO
ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Cylinder Reed Displacement . . . . . . . . . . . . . . . 438 cc Bore . . . . . . . . . . . . . . . . . . . . . . . 2.579〉 (65.5mm) Stroke . . . . . . . . . . . . . . . . . . . . . 2.559〉 (65mm) Piston / Cylinder Clearance . . . 0.0028〉 - 0.0041〉 (0.070 - 0.105 mm) Piston Marking . . . . . . . . . . . . . . 4RA Piston Ring Marking . . . . . . . . . 4N Piston Ring End Gap . . . . . . . . 0.012 - 0.018 (.3 - .45 mm) Head cc’s .4cc (Uninstalled) . . . . . . . . 24.2 cc Head cc’s .4cc (Installed) . . . . . . . . . . . 21.2 cc Operating RPM 200 . . . . . . . . . 7750 RPM Idle RPM 200 . . . . . . . . . . . . . . 1600 RPM Engagement RPM 300 . . . . . . 4600 RPM Cylinder Head Torque . . . . . . . . 18-19 ft.lbs (2.5-2.8 kg-m) Cylinder Base Nut Torque . . . . 24-28 ft.lbs (3.3-3.9 kg-m) Crankcase Torque (8mm) . . . . . 17-18 ft.lbs (2.2-2.3 kg-m) Crankcase Torque (10mm) . . . 23-25 ft.lbs (3.2-3.5 kg-m) Flywheel Torque . . . . . . . . . . . . . 60-65 ft.lbs (8.3-9 kg-m)
1.8
DRIVEN
Shift Weight
GENERAL INFORMATION MODEL: . . . . . . . . . . XCF SP MODEL NUMBER: . S01NX4FS ENGINE MODEL: . . EC45PM022
ELECTRICAL
CAPACITIES
Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .
F004T32971 17620201 240 Watts @ 4000 RPM 27 BTDC@3000RPM 1.5 0.175〉 BTDC (0.157〉-0.195〉) 4.45mm BTDC (3.97-4.93mm) Spark Plug / Gap . . . NGK BR9ES / 0.028” (0.7mm) Lights: Head . . . . . . 2 60 High/50 Low Tail . . . . . . . . 2@3 watts Brake . . . . . . 18 watts Voltage Regulator . . LR7 Electric Start . . . . . . . Option *LR9= Half wave voltage regulator
Fuel Tank . . . . . . . . . . Oil Tank . . . . . . . . . . . . Coolant . . . . . . . . . . . . Chaincase Oil . . . . . . .
SUSPENSION / CHASSIS
CHAINCASE
Body Style . . . . . . . . Front Suspension . . Front Shocks . . . . . . IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Travel . . . . . . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .
11.8 Gal. (45.4 L) 3.5 Quarts (3.3 L) N/A 8 oz.
EDGE Pro X Sprockets / Chain . . . 22-43, 74 P 3/4HYVO EDGE Pro X Reverse . . . . . . . . . . . . Option Arvin Ryde FXt Brake Pads . . . . . . . . . Type 81 130#/in. Chaincase Center Dist.7.658 (19.45cm) 1.88〉 Thread Adjust Driveshaft Sprockets . 2 Drivers 9.36〉 (23.77 cm.) Brake Type . . . . . . . . . Polaris HPB EDGE Pro X 13.86〉 (35.20 cm.) Arvin Emulsiont 170#/in. Arvin Ryde FXt Clicker .359〉 / 77 15〉x121〉x.82〉 (38.1x307.34x2.08cm.) 1 1/2” (38mm) slack with 10# (4.54kg) weight 16” (40.64cm.) ahead of rear idler shaft
OPTIONAL REAR TORSION SPRINGS 2001 XCF SP/440 Edge Pro X Rear Torsion Springs SOFT
MEDIUM(STD)
FIRM
.347〉(sq.) diameter/77
.359〉(sq.) diameter/77
.375〉(sq.) diameter/77
L.H 7041627-067
L.H. 7041629-067
L.H. 7041631-067
R.H. 7041628-067
R.H 7041630-067
R.H. 7041632-067
1.9
GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . 440 Edge Pro X MODEL NUMBER: . S01NX4CS ENGINE MODEL: . . S44-44-PO 2093 JETTING CHART AMBIENT TEMPERATURE
Altitude
CARBURETION Type . . . . . . . . . . . . . . . . TMX-34 Mikuni Main Jet . . . . . . . . . . . . 350 Pilot Jet . . . . . . . . . . . . . 22.5 Jet Needle . . . . . . . . . . . 6GL64--61--3 Needle Jet . . . . . . . . . . . Q-8 (Fixed) Cutaway . . . . . . . . . . . . 2.5 Air Screw . . . . . . . . . . . 1.0 Turns Valve Seat . . . . . . . . . . . 1.5 Viton Fuel Octane w/o Ethanol (R+M/2) 92 Octane Prem. Unlead. Throttle Gap Under Cutaway . . . . . . .098〉(2.5 mm) (Engine side) Exhaust Valve Spring Red/White
CLUTCH Type . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . Belt Width (Projected) . Side Angle (Overall) . . Outside Circumference Center Distance . . . . . . Shift Weights . . . . . . . . Primary Spring . . . . . . . Secondary Spring . . . . Driven Helix . . . . . . . . .
P-85 3211080 1.438〉 (34.93mm) 28 46.625” (118.43cm.) 11.5〉 (305mm) S53H Almond/Red Blue/Orange R-49 #2
Meters (Feet)
Below -20F -20 F Below -29C
-20 to +10_F -20_ +10 F -29_to -12_C
+10 to +40_F +10_to +40 F -12_ to +5_C
Above +40_F +40 F Above 5_C
0-900 0 900 (0-3000) (0 3000)
390 #3
370 #3
340 #3
320 #3
900-1800 900 1800 (3000-6000) (3000 6000)
350 #3
330 #3
310 #3
290 #3
1800-2700 1800 2700 (6000-9000) (6000 9000)
320 #3
300 #3
280 #3
260 #3
2700-3700 2700 3700 (9000-12000) (9000 12000)
280 #3
270 #3
250 #3
230 #3
XXX #X - # refers to the clip position from top of jet needle.
CLUTCH CHART DRIVE
Altitude Meters (Feet)
DRIVEN
Shift Weight
Clutch Spring
Clutch Spring
Driven Helix
Chaincase Gearing
0-900 (0-3000)
S53H
Almond Red
Blue/ Orange
R49 #2
22:43 74P
900-1800 (3000-6000)
S51H
Almond Red
Blue/ Orange
R49 #3
22:43 74P
1800-2700 (6000-9000)
S49H
Almond Red
Blue/ Orange
R49 #3
22:43 74P
2700-3700 (9000-12000)
S49H
Almond Red
Blue/ Orange
R49 #3
22:43 74P
Note: Production main jet is a 350 for 92 octane fuel. Do not run below 0_F at 0--1000 feet. Standard timing curve position = “D”.
Timing positions pg 2.12 Fine Tuning jetting chart p1.3 ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Service Limit . . . . . . . . . . . . . . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head cc’s (Uninstalled) . . . . . . . Head cc’s (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 . . . . . . . . . . . . .
1.10
Liquid Cooled Case Reed w/V.E.S. 438 cc 2.598〉 (66mm) 2.520〉 (64mm) 0.0023〉 - 0.0037〉(0.06 - 0.095mm) 0.0059〉 (0.15mm) EK2185/28 “o” faces upward .008〉-.020〉(.20-.51mm) TBA TBA 8750 RPM 1600 RPM 5000 RPM 20-24 ft.lbs(2.8-3.3 kgm) 30-34 ft.lbs(4.15-4.7 kgm) 20-24 ft.lbs(2.8-3.3 kgm) N/A 90 ft.lbs(12.4 kgm)
GENERAL INFORMATION MODEL: . . . . . . . . . . 440 Edge Pro X MODEL NUMBER: . S01X4CS ENGINE MODEL: . . S44-44-PO 2093
ELECTRICAL
CAPACITIES
Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . .
4010523 Fuel Tank . . . . . . . . . . 4010469 Oil Tank . . . . . . . . . . . . 280 Watts Coolant . . . . . . . . . . . . 22 BTDC@4500RPM 1.5 Chaincase Oil . . . . . . . .with pipe sensor unplugged Spark Plug / Gap . . . Champion RN-57YCC / 0.028” (0.7mm) PN 3070190 Lights: Head . . . . . . 2 60High/50Low Tail . . . . . . . . 2@2 watts Brake . . . . . . 1@17 watts Voltage Regulator . . LR7 Electric Start . . . . . . . N/A *LR7= Full wave voltage regulator
SUSPENSION / CHASSIS Body Style . . . . . . . . Front Suspension . . Front Shocks . . . . . . ................... ................... IFS Spring Rate . . . . Front Spring Preload Front Vertical Travel Rear Suspension . . . Rear Travel . . . . . . . . Front Track Shock . . Spring Rate . . . . . . . . Rear Track Shock . . Rear Springs . . . . . . Track Type . . . . . . . . Track Tension . . . . . .
11.8 Gal. (45.4 L) 2.0 Quarts (3.3 L) 4 Quarts (3.78 L) 9 oz.
CHAINCASE
EDGE Sprockets / Chain . . . 21-41, 74 P 3/4 HYVO EDGE PRO -- X Reverse . . . . . . . . . . . . N/A Arvin IFP piggy back remote . . . Brake Pads . . . . . . . . . Wilwood reservoir w/ Externally adjustable Chaincase Center Dist.7.658”(19.54.) compression damping. . . . . . . . . . Driveshaft Sprockets . 2 Drivers-wide 120/220#/in. . . . . . . Brake Type . . . . . . . . . Willwood Dual Piston TBA〉 Thread Adjust 9.00〉 (26.46 cm..) EDGE PRO X 13.90〉 (35.31 cm..) Arvin IFP remote reservoir w/externally adjustable compression damping 170#/in. Arvin IFP remote reservoir w/externally adjustable compression damping .359〉 (sq.) / 77 15〉x121〉x1.25〉 (38.1x307.34x3.175cm.) 1 1/2〉 (38mm) slack with 10# (4.54kg) weight 16〉 (40.64cm.) ahead of rear idler shaft
OPTIONAL REAR TORSION SPRINGS 2000 XCF SP/440 Edge Pro X Rear Torsion Springs SOFT
MEDIUM(STD)
FIRM
.347〉(sq.) diameter/77
.359〉(sq.) diameter/77
.375〉(sq.) diameter/77
L.H 7041627-067
L.H. 7041629-067
L.H. 7041631-067
R.H. 7041628-067
R.H 7041630-067
R.H. 7041632-067
1.11