2001 Polaris Indy 800 XCR SNOWMOBILE Service Repair Manual

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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 famil- iar 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 impor- tance. 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.
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Transcript of 2001 Polaris Indy 800 XCR SNOWMOBILE Service Repair Manual

  • 2001 HIGH PERFORMANCESERVICE MANUAL

    ForewordThis manual is designed primarily for use by Polaris snowmobile service technicians in a properly equippedshop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shopprocedures in order to perform the work safely and correctly. The technician should read the text and be famil-iar with service procedures before starting the work. Certain procedures require the use of special tools. Useonly the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor-tance.

    All references to left and right side of the vehicle are from the operator’s perspective when seated in a normalriding position.This manual includes procedures for maintenance operations, component identification and unit repair, alongwith service specifications for the 2001 Polaris snowmobiles. A table of contents is placed at the beginning ofeach chapter, and an alphabetic index is provided at the end of the manual for location of specific pagenumbers 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, allmaterials and specifications are subject to change without notice.Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service PublicationsDepartment, 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

  • 1CHAPTER 1GENERAL INFORMATION

    High Performance parts 1.1--1.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Initial Break--In 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Race Support 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Publication numbers 1.5--1.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, XCF SP 1.8--1.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 440 EDGE Pro X 1.10--1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 600 EDGE Pro X 1.12--1.13. . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 500 XC EDGE 1.14--1.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 500 XC SP 1.16-1.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 600 XC SP, EDGE X 1.18--1.19. . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 700 XC SP 1.20--1.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 800 XC SP 1.22--1.23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 800 XCR 1.24--1.25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 500 RMK 1.26--1.27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 600 RMK 1.28--1.29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 700 RMK 1.30--1.31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications, 800 RMK, S.C. SP 1.32--1.33. . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Specifications 1.34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Decimal Equivalent Chart 1.35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Conversion Table 1.36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tap Drill Charts 1.37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glossary of Terms 1.38--1.40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Tips 1.41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Set Up Tips 1.42--1.49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • GENERAL INFORMATION

    1.1

    PART DESCRIPTION

    NUMBER

    Fox Shocks

    2900153 REMOTE RESERVOIR REAR TRACK (RACE)

    2900152 REMOTE RESERVOIR REAR TRACK (TRAIL)

    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

    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

    2900047 Ramp, driven, R12, 50--36

    2900048 Ramp, driven, 42 / 36 / 34

    Weights

    2900026 WEIGHT,SHIFT,MATCHED,10--60

    2900027 WEIGHT,SHIFT,MATCHED,10--56

    2900028 WEIGHT,SHIFT,MATCHED,10--54

    2900029 WEIGHT,SHIFT,MATCHED,10--58

    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)

    PART DESCRIPTION

    NUMBER

    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

    5521587--309 EDGE EXTRA WIDE RAIL SLIDERS (01 EDGE Racer)

    5521556--309 EDGE EXTRA WIDE RAIL SLIDERS (00--01 EDGE)

    2900067 TIE DOWN KIT,HOOD

    Hood/Seat

    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

    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

  • GENERAL INFORMATION

    1.2

    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

    HYVO Chain

    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

    Motor Mounts

    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

    Tracks

    2900019 TRACK,121”X1.5 --NOTCHED

    2900018 TRACK,121”X--1.75 --NOTCHED

    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

    1.3

    Polaris’ new 440 Edge Pro X and XCF SP edge models have been designed and tested to endure the toughestof all races. Many hours of testing have gone into development, and engineering has decided to use a predeter-mined weight rider and snow cross racing for stock setup. After uncrating your machine, be sure to test ride sosetup can be determined for your riding style and characteristics. The following are setup tips for your brand new440 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 whatyou 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 toensure the performance of your machine will be at its peak.

    1. Always break-in any new part for 50-75 miles before using it for racing.2. Clutch springs and belts need to be broken in to reach their peak in performance.3. On the 440 Edge Pro X, always use the correct type of fuel for the timing system you are using.4. Always use the recommended Polaris oil for your snowmobile.5. Always break-in a new or rebuilt engine to ensure durability.6. Maintain your exhaust valves frequently to ensure they are operating to their fullest capability.

    440 Jetting for Temperature and Altitude

  • GENERAL INFORMATION

    1.4

    South Side Race Support:Contact: Bruce Gaspardi546 Curran Hwy.North Adams, MA 01247Phone: (413) 664-7111Racing: Cross country, SnowcrossService 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, miscella-neous hardware.

    Wahl Brothers Racing:Contact: DaveHwy 11 WestGreenbush, MN 56726Phone: (218) 782-2295Racing: AllService Capabilities: OEM parts, Foxt shock rebuilding and valving, lubricants, traction products, clutch disas-sembly, miscellaneous hardware.

    Karkoulas Racing:Contact: Troy KarkoulasS2225 Scugog Brock Town LineSunderland ON Canada L0C 1H0Phone: (705) 357--1226Racing: All

    Polaris Racing10303 Calumet Ave.Suite # 3Mosinee, WI 54455Phone: (715) 355--5157Fax: (715) 355--8797

    GENERAL INFORMATION

  • GENERAL INFORMATION

    1.5

    2001 Publication Numbers

    Model Model No. Owner’s ManualSupplement

    PartsManual

    PartsMicrofiche

    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 ManualSupplement

    PartsManual

    PartsMicrofiche

    XCF XC SP S00NX4FS 9915615 9915616 9915617

    440 XC SP S00NX4CS 9915372 9915402 9915430

    500 XC SP 45thAnniversary

    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

  • GENERAL INFORMATION

    1.6

    Service Manuals

    120 XC SP 2001 9916684

    Trail Sport340 DLX, Indy 500 EDGE, SuperSport EDGE 2001 9916685

    Two-Up / TouringWide Trak LX, 340 Touring, Sport Touring, Sport Touring ES, 500Classic Touring, 600 Classic Touring

    2001 9916686

    Trail Luxury500 Classic, 600 Classic, 700 Classic, 800 LE 2001 9916687

    Deep Snow700 SKS, Trail RMK, 500/600/700/800 RMK, 800 RMK Snow-check Special

    2001 9916688

    Performance500 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 Setw/wallcharts (all models except

    race)

    2000 9915986

    Fan Cooled Models 2000 9915980

    Mid Range Liquid Cooled (500s,600 triple)

    2000 9915981

    Performance Liquids (600twins,700s, 800s)

    2000 9915982

    120 XCR 2000 9915983

    High Performance (Race) 2000 9915985

    Wall Chart Packet only 2000 9915984

    GENERAL INFORMATION

  • GENERAL INFORMATION

    1.7

    2001 Specifications

    440 XCF SP440 Edge Pro X600 Edge Pro X500 XC Edge500 XC SP Edge600 XC SP, X Edge700 XC SP Edge800 XC SP Edge500 RMK600 RMK700 RMK800 RMK, S.C. Special

  • GENERAL INFORMATION

    1.8

    MODEL: XCF SP. . . . . . . . . .MODEL NUMBER: S01NX4FS.ENGINE MODEL: EC45PM022. .

    JETTING CHARTAMBIENT TEMPERATURE

    Altitude Below -20F -20_ to +10_F +10_to +40_F Above +40_FAltitude Below -20 FBelow -29C

    -20 to +10 F-29_to -12_C

    +10 to +40 F-12_ to +5_C

    Above +40 FAbove 5_C

    Meters(Feet)

    0-900(0-3000)

    PTO 360MAG 350

    PTO 340MAG 330

    PTO 320MAG 310

    PTO 300MAG 290(Feet) (0-3000) MAG 350

    #3MAG 330

    #3MAG 310

    #3MAG 290

    #3

    900-1800(3000-6000)

    PTO 320MAG 310

    PTO 310MAG 300

    PTO 290MAG 280

    PTO 270MAG 260(3000-6000) MAG 310

    #3MAG 300

    #3MAG 280

    #3MAG 260

    #2

    1800-2700(6000-9000)

    PTO 290MAG 280

    PTO 270MAG 260

    PTO 260MAG 250

    PTO 240MAG 230(6000-9000) MAG 280

    #3MAG 260

    #3MAG 250

    #2MAG 230

    #22700-3700

    (9000-12000)PTO 260MAG 250

    PTO 250MAG 240

    PTO 230MAG 220

    PTO 220MAG 210(9000-12000) MAG 250

    #3MAG 240

    #2MAG 220

    #2MAG 210

    #2

    XXX#X

    - # refers to the clip position from top of jet needle.

    - Production Setting

    CLUTCH CHART

    DRIVE DRIVENAltitude Shift Clutch Clutch Driven ChaincaseAltitude Shift

    WeightClutchSpring

    ClutchSpring

    DrivenHelix

    ChaincaseGearing

    Meters 0-900 10-54 Almond/ Silver R5 22--43 PMeters(Feet)

    0-900(0-3000)

    10-54Bushed

    Almond/Red

    SilverBlue

    R5#-2

    22--43 PHYVO

    900-1800 10-54 Almond/ Silver R5 22--43 74 P900-1800(3000-6000)

    10-54Bushed

    Almond/Red

    SilverBlue

    R5#-2

    22--43 74 PHYVO

    1800-2700 10 Almond/ Silver R522--43 74 P1800-2700

    (6000-9000) 10Almond/

    RedSilverBlue

    R5#-2

    22--43 74 PHYVO

    2700-3700 10 Almond/ Silver R522--43 74 P2700-3700

    (9000-12000) 10Almond/

    RedSilverBlue

    R5#-2

    22--43 74 PHYVO

    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). . . . . . . . . . . . .

    CARBURETIONType VM34AL Mikuni. . . . . . . . . . . . . . . .Main Jet 340 PTO/330 MAG. . . . . . . . . . . .Pilot Jet 45. . . . . . . . . . . . .Jet Needle 6DHK06--03. . . . . . . . . . .Needle Jet Q-2(286). . . . . . . . . . .Cutaway 3.0. . . . . . . . . . . .Air Screw 1.0 Turns. . . . . . . . . . .Valve Seat 1.5 Viton. . . . . . . . . . .Fuel Octane (R+M/2) 87 Non-Oxygenated or.

    89 OxygenatedThrottle GapUnder Cutaway .244〉 -(6.2mm). . . . . .Idle Sync GapUnder Cutaway .218〉 - (5.54mm). . . . . .

    CLUTCHType P-85. . . . . . . . . . . . . . . .Belt 3211078. . . . . . . . . . . . . . . . .Belt Width (Projected) 1 7/16〉.Side Angle (Overall) 28. .Outside Circumference 56 5/8〉Center Distance 11.50〉. . . . . .Shift Weights 10-54. . . . . . . .Primary Spring Almond Red. . . . . . .Secondary Spring Silver/Blue. . . .Driven Helix R5 #2. . . . . . . . .

    GENERAL INFORMATION

  • GENERAL INFORMATION

    1.9

    MODEL: XCF SP. . . . . . . . . .MODEL NUMBER: S01NX4FS.ENGINE MODEL: EC45PM022. .

    ELECTRICAL CAPACITIESFlywheel I.D. F004T32971 Fuel Tank 11.8 Gal. (45.4 L). . . . . . . . . . . . . . . .CDI Marking 17620201 Oil Tank 3.5 Quarts (3.3 L). . . . . . . . . . . . . . . . . . .Alternator Output 240 Watts @ 4000 RPM Coolant N / A. . . . . . . . . . . . . . .Ignition Timing 27 [email protected]�1.5 Chaincase Oil 8 oz.. . . . . . . . . . . .

    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 [email protected] watts. . . . . . . .Brake 18 watts. . . . . .

    Voltage Regulator LR7. .Electric Start Option. . . . . . .*LR9= Half wave voltage regulator

    SUSPENSION / CHASSIS CHAINCASEBody Style EDGE Pro X Sprockets / Chain 22-43, 74 P 3/4HYVO. . . . . . . . . . .Front Suspension EDGE Pro X Reverse Option. . . . . . . . . . . . . .Front Shocks Arvin Ryde FXt Brake Pads Type 81. . . . . . . . . . . . . . .IFS Spring Rate 130#/in. Chaincase Center Dist.7.658 (19.45cm). . . .Front Spring Preload 1.88〉 Thread Adjust Driveshaft Sprockets 2 Drivers.Front Vertical Travel 9.36〉 (23.77 cm.) Brake Type Polaris HPB. . . . . . . . .Rear Suspension EDGE Pro X. . .Rear Travel 13.86〉 (35.20 cm.). . . . . . . .Front Track Shock Arvin Emulsiont. .Spring Rate 170#/in.. . . . . . . .Rear Track Shock Arvin Ryde FXt Clicker. .Rear Springs .359〉 / 77. . . . . .Track Type 15〉x121〉x.82〉 (38.1x307.34x2.08cm.). . . . . . . .Track Tension 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 SpringsSOFT 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

  • 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.

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  • GENERAL INFORMATION

    1.10

    MODEL: 440 Edge Pro X. . . . . . . . . .MODEL NUMBER: S01NX4CS.ENGINE MODEL: S44-44-PO 2093. .

    JETTING CHARTAMBIENT TEMPERATURE

    Altitude Below -20F -20_ to +10_F +10_to +40_F Above +40_FAltitude Below -20 FBelow -29C

    -20 to +10 F-29_to -12_C

    +10 to +40 F-12_ to +5_C

    Above +40 FAbove 5_C

    Meters 0-900(0 3000)

    390 370 340 320Meters(Feet)

    0 900(0-3000)

    390#3

    370#3

    340#3

    320#3

    900-1800(3000 6000)

    350 330 310 290900 1800(3000-6000)

    350#3

    330#3

    310#3

    290#3

    1800-2700(6000 9000)

    320 300 280 2601800 2700(6000-9000)

    320#3

    300#3

    280#3

    260#3

    2700-3700(9000 12000)

    280 270 250 2302700 3700(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 DRIVENAltitude Shift Clutch Clutch Driven ChaincaseAltitude Shift

    WeightClutchSpring

    ClutchSpring

    DrivenHelix

    ChaincaseGearing

    Meters 0-900 S53H Almond Blue/ R4922:43Meters

    (Feet)0-900

    (0-3000) S53HAlmond

    RedBlue/

    OrangeR49#2

    22:4374P

    900-1800 S51H Almond Blue/ R4922:43900-1800

    (3000-6000) S51HAlmond

    RedBlue/

    OrangeR49#3

    22:4374P

    1800-2700 S49H Almond Blue/ R4922:431800-2700

    (6000-9000) S49HAlmond

    RedBlue/

    OrangeR49#3

    22:4374P

    2700-3700 S49H Almond Blue/ R4922:432700-3700

    (9000-12000) S49HAlmond

    RedBlue/

    OrangeR49#3

    22:4374P

    ENGINEType Liquid Cooled Case Reed w/V.E.S.. . . . . . . . . . . . . . . . . . . . . . .Displacement 438 cc. . . . . . . . . . . . . . .Bore 2.598〉 (66mm). . . . . . . . . . . . . . . . . . . . . . .Stroke 2.520〉 (64mm). . . . . . . . . . . . . . . . . . . . .Piston / Cylinder Clearance 0.0023〉 - 0.0037〉(0.06 - 0.095mm). . .Service Limit 0.0059〉 (0.15mm). . . . . . . . . . . . . . . .Piston Marking EK2185/28. . . . . . . . . . . . . .Piston Ring Marking “o” faces upward. . . . . . . . .Piston Ring End Gap .008〉-.020〉(.20-.51mm). . . . . . . .Head cc’s (Uninstalled) TBA. . . . . . .Head cc’s (Installed) TBA. . . . . . . . .Operating RPM�200 8750 RPM. . . . . . . . .Idle RPM�200 1600 RPM. . . . . . . . . . . . . .Engagement RPM�300 5000 RPM. . . . . .Cylinder Head Torque 20-24 ft.lbs(2.8-3.3 kgm). . . . . . . .Cylinder Base Nut Torque 30-34 ft.lbs(4.15-4.7 kgm). . . .Crankcase Torque (8mm) 20-24 ft.lbs(2.8-3.3 kgm). . . . .Crankcase Torque (10mm) N/A. . .Flywheel Torque 90 ft.lbs(12.4 kgm). . . . . . . . . . . . .

    CARBURETIONType 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 GapUnder Cutaway .098〉(2.5 mm). . . . . .(Engine side)Exhaust Valve Spring Red/White

    CLUTCHType P-85. . . . . . . . . . . . . . . .Belt 3211080. . . . . . . . . . . . . . . . .Belt Width (Projected) 1.438〉 (34.93mm).Side Angle (Overall) 28. .Outside Circumference 46.625” (118.43cm.)Center Distance 11.5〉 (305mm). . . . . .Shift Weights S53H. . . . . . . .Primary Spring Almond/Red. . . . . . .Secondary Spring Blue/Orange. . . .Driven Helix R-49 #2. . . . . . . . .

    Note: Production main jet is a 350 for 92 octanefuel. Do not run below 0_F at 0--1000 feet. Standard tim-

    ing curve position = “D”.

    Timing positions pg 2.12Fine Tuning jetting chart p1.3

    GENERAL INFORMATION

  • GENERAL INFORMATION

    1.11

    MODEL: 440 Edge Pro X. . . . . . . . . .MODEL NUMBER: S01X4CS.ENGINE MODEL: S44-44-PO 2093. .

    ELECTRICAL CAPACITIESFlywheel I.D. 4010523 Fuel Tank 11.8 Gal. (45.4 L). . . . . . . . . . . . . . . .CDI Marking 4010469 Oil Tank 2.0 Quarts (3.3 L). . . . . . . . . . . . . . . . . . .Alternator Output 280 Watts Coolant 4 Quarts (3.78 L). . . . . . . . . . . . . . .Ignition Timing 22 [email protected]�1.5 Chaincase Oil 9 oz.. . . . . . . . . . . .

    .with pipe sensor unpluggedSpark Plug / Gap Champion RN-57YCC / 0.028” (0.7mm) PN 3070190. . .Lights: Head 2 60High/50Low. . . . . .

    Tail [email protected] watts. . . . . . . .Brake [email protected] watts. . . . . .

    Voltage Regulator LR7. .Electric Start N/A. . . . . . .*LR7= Full wave voltage regulator

    SUSPENSION / CHASSIS CHAINCASEBody Style EDGE Sprockets / Chain 21-41, 74 P 3/4 HYVO. . . . . . . . . . .Front Suspension EDGE PRO -- X Reverse N/A. . . . . . . . . . . . . .Front Shocks 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    IFS Spring Rate 120/220#/in. Brake Type Willwood Dual Piston. . . . . . . . . . . . . . . . . . .Front Spring Preload TBA〉 Thread AdjustFront Vertical Travel 9.00〉 (26.46 cm..)Rear Suspension EDGE PRO X. . .Rear Travel 13.90〉 (35.31 cm..). . . . . . . .Front Track Shock Arvin IFP remote reservoir w/externally adjustable compression damping. .Spring Rate 170#/in.. . . . . . . .Rear Track Shock Arvin IFP remote reservoir w/externally adjustable compression damping. .Rear Springs .359〉 (sq.) / 77. . . . . .Track Type 15〉x121〉x1.25〉 (38.1x307.34x3.175cm.). . . . . . . .Track Tension 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 SpringsSOFT 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

  • GENERAL INFORMATION

    1.12

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

    JETTING CHARTAMBIENT TEMPERATURE

    Altitude Below -20F -20_ to +10_F +10_to +40_F Above +40_FAltitude Below -20 FBelow -29C

    -20 to +10 F-29_to -12_C

    +10 to +40 F-12_ to +5_C

    Above +40 FAbove 5_C

    Meters(F )

    0-900(0 3000)

    450 420 390 370Meters(Feet) (0-3000)

    450#3

    420#3

    390#3

    370#3

    900-1800(3000 6000)

    410 380 360 340900 1800(3000-6000)

    410#3

    380#3

    360#3

    340#2

    1800-2700(6000 9000)

    370 340 320 3001800 2700(6000-9000)

    370#3

    340#3

    320#2

    300#2

    2700-3700(9000 12000)

    320 310 290 2702700 3700(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 DRIVENAltitude Shift Clutch Clutch Driven ChaincaseAltitude Shift

    WeightClutchSpring

    ClutchSpring

    DrivenHelix

    ChaincaseGearing

    Meters 0-900 10 58 Almond Silver/ R1124--41 74 PMeters

    (Feet)0-900

    (0-3000) 10--58Almond

    RedSilver/Blue

    R11#2

    24--41 74 PHYVO

    900-1800 10 56 Almond Silver/ R1124-41 74 P900-1800

    (3000-6000) 10--56Almond

    RedSilver/Blue

    R11#2

    24-41 74 PHYVO

    1800-2700 10 54 Almond Silver/ R1124 41 74 P1800-2700

    (6000-9000) 10--54Almond

    RedSilver/Blue

    R11#2

    24 41 74 PHYVO

    2700-3700 10 54 Almond Silver/ R1124-41 74 P2700-3700

    (9000-12000) 10--54Almond

    RedSilver/Blue

    R11#3

    24-41 74 PHYVO

    ENGINEType Liquid Cooled Case Reed w/VES Engine Compression 120 psi. . . . . . . . . . . . . . . . . . . . . . . . . .Displacement 600cc Fuel Pump Manuf. Walbro. . . . . . . . . . . . . . . . . . . .Bore 3.041〉 (77.25mm) Fuel Pump Mark E-806. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stroke 2.520 (64mm) Oil Pump Manuf. Mikuni. . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston / Cylinder Clearance .0045〉-.0059〉 (.11-.15mm) Oil Pump Mark 02A. . . . . . . . . . .Piston Marking 2202a Cylinder Head Mark 3022057. . . . . . . . . . . . . . . . . .Piston Ring Marking N/A. . . . . . . . .Piston Ring End Gap .014〉-.020〉 (.38-.51mm). . . . . . . .Head ccs (Uninstalled) 36-37cc. . . . . . .Head ccs (Installed) 29-30cc. . . . . . . . .Operating RPM�200 8000. . . . . . . . .Idle RPM�100 1500. . . . . . . . . . . . . .Engagement RPM�200 4800. . . . . .Cylinder Head Torque 20-24 ft.lbs. (28-33 Nm). . . . . . . .Cylinder Base Nut Torque 30-34 ft.lbs. (41-47 Nm). . . .Crankcase Torque (8mm) 20-24 ft.lbs. (28-33 Nm). . . . .Crankcase Torque (10mm) N/A. . .Flywheel Torque 90 ft.lbs. (124 Nm). . . . . . . . . . . . .

    CLUTCHType P-85. . . . . . . . . . . . . . . .Belt 3211080. . . . . . . . . . . . . . . . .Belt Width (Projected) 1.438〉 (34.93mm).Side Angle (Overall) 28. .Outside Circumference 46.625“(118.43)Center Distance 11.5〉 (305mm). . . . . .Shift Weights 10--58. . . . . . . .Primary Spring Almond Red. . . . . . .Secondary Spring Silver/Blue. . . .Driven Helix R-11 #2. . . . . . . . .

    CARBURETIONType (2) TM 38 Mikuni w/TPS. . . . . . . . . . . . . . . .Main Jet 420. . . . . . . . . . . .Pilot Jet 45. . . . . . . . . . . . .Jet Needle J8--9DFH7-60-2. . . . . . . . . . .Needle Jet P-8. . . . . . . . . . .Cutaway 1.5. . . . . . . . . . . .Air Screw N/A. . . . . . . . . . .Valve Seat 1.5 Viton. . . . . . . . . . .Fuel Octane (R+M/2) Key Switch Adjustable.Throttle GapUnder Cutaway .091”(2.3mm). . . . . .Pilot Air Jet 0.7 Long. . . . . . . . . .Starter Jet 140. . . . . . . . . . .Fuel Screw 1.5 Turns. . . . . . . . . .Exhaust Valve Spring Green/Yellow.

    GENERAL INFORMATION