Page 1

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


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 -20 -20F F Below -29C

-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 +40_F 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 RPM200 . . . . . . . . . 7750 RPM Idle RPM200 . . . . . . . . . . . . . . 1600 RPM Engagement RPM300 . . . . . . 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@3000RPM1.5 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


Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.


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 -20 -20F F Below -29C

-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 +40_F 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 RPM200 . . . . . . . . . Idle RPM200 . . . . . . . . . . . . . . Engagement RPM300 . . . . . . 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@4500RPM1.5 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


GENERAL GENERAL INFORMATION INFORMATION MODEL: . . . . . . . . . . 600 Edge Pro X MODEL NUMBER: . S01NX6ES ENGINE MODEL: . . S60--44--PO--6E--2234

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Cutaway . . . . . . . . . . . . Air Screw . . . . . . . . . . . Valve Seat . . . . . . . . . . . Fuel Octane (R+M/2) . Throttle Gap Under Cutaway . . . . . . Pilot Air Jet . . . . . . . . . . Starter Jet . . . . . . . . . . . Fuel Screw . . . . . . . . . . Exhaust Valve Spring .

JETTING CHART (2) TM 38 Mikuni w/TPS 420 45 J8--9DFH7-60-2 P-8 1.5 N/A 1.5 Viton Key Switch Adjustable .091”(2.3mm) 0.7 Long 140 1.5 Turns Green/Yellow

AMBIENT TEMPERATURE

Altitude Meters (F ) (Feet)

Below -20 -20F F Below -29C

-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 +40_F F Above 5_C

0-900 (0-3000) (0 3000)

450 #3

420 #3

390 #3

370 #3

900-1800 900 1800 (3000-6000) (3000 6000)

410 #3

380 #3

360 #3

340 #2

1800-2700 1800 2700 (6000-9000) (6000 9000)

370 #3

340 #3

320 #2

300 #2

2700-3700 2700 3700 (9000-12000) (9000 12000)

320 #3

310 #2

290 #2

270 #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 3211080 1.438〉 (34.93mm) 28 46.625“(118.43) 11.5〉 (305mm) 10--58 Almond Red Silver/Blue R-11 #2

Meters (Feet)

DRIVEN

Shift Weight

Clutch Spring

Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 -58 1058

Almond Red

Silver/ Blue

R11 #2

24--41 74 P HYVO

900-1800 (3000-6000)

10 -56 1056

Almond Red

Silver/ Blue

R11 #2

24-41 74 P HYVO

1800-2700 (6000-9000)

10 -54 1054

Almond Red

Silver/ Blue

R11 #2

24 41 74 P HYVO

2700-3700 (9000-12000)

10 -54 1054

Almond Red

Silver/ Blue

R11 #3

24-41 74 P HYVO

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Piston / Cylinder Clearance . . . Piston Marking . . . . . . . . . . . . . . Piston Ring Marking . . . . . . . . . Piston Ring End Gap . . . . . . . . Head ccs (Uninstalled) . . . . . . . Head ccs (Installed) . . . . . . . . . Operating RPM200 . . . . . . . . . Idle RPM100 . . . . . . . . . . . . . . Engagement RPM200 . . . . . . Cylinder Head Torque . . . . . . . . Cylinder Base Nut Torque . . . . Crankcase Torque (8mm) . . . . . Crankcase Torque (10mm) . . . Flywheel Torque . . . . . . . . . . . . .

1.12

Liquid Cooled Case Reed w/VES 600cc 3.041〉 (77.25mm) 2.520 (64mm) .0045〉-.0059〉 (.11-.15mm) 2202a N/A .014〉-.020〉 (.38-.51mm) 36-37cc 29-30cc 8000 1500 4800 20-24 ft.lbs. (28-33 Nm) 30-34 ft.lbs. (41-47 Nm) 20-24 ft.lbs. (28-33 Nm) N/A 90 ft.lbs. (124 Nm)

Engine Compression . . . Fuel Pump Manuf. . . . . . Fuel Pump Mark . . . . . . . Oil Pump Manuf. . . . . . . . Oil Pump Mark . . . . . . . . Cylinder Head Mark . . . .

120 psi Walbro E-806 Mikuni 02A 3022057

Profile for 1637943

2001 Polaris Indy 800 XCR SNOWMOBILE Service Repair Manual  

2001 Polaris Indy 800 XCR SNOWMOBILE Service Repair Manual  

Profile for 1637943
Advertisement