2004 polaris 800 pro xr snowmobile service repair manual

service repair manual

1. o
Master Cover 280 2Hits 10/8/03 10:39 PM Page 1

2. WIRING DIAGRAMS
ELECTRICAL
FINAL DRIVE
FRONT SUSPENSION
CHASSIS
CLUTCHING
FUEL DELIVERY
ENGINE
MAINTENANCE
GENERAL
BRAKES
STEERING
INDEX
REAR SUSPENSION
SPECIFICATIONS

3. Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Willwood, Trademark of the Willwood Corporation
Walker Evans Racing Shocks, Trademark of the Walker Evans Ent.

4. 440 PRO X 1.1 -- 1.2..........................................
550 PRO X 1.3 -- 1.4..........................................
600 PRO X (X2) 1.5 -- 1.6......................................
700 PRO X (X2) 1.7 -- 1.8......................................
800 PRO X (X2) 1.9 -- 1.10......................................
800 PRO XR 1.11 -- 1.12........................................
PRO X Engine Specifications 1.13..........................

5. SPECIFICATIONS
1.1
MODEL: 440 PRO XR..............
MODEL NUMBER: S04NX4CS.....
ENGINE MODEL: S2460--4444--PR4C......
ENGINE CARBURETION
Engine Type Domestic Type
Mikuni
TMX 34
Engine Displacement cc 438 Main Jet 290
Bore in / mm 2.60” / 66mm Pilot Jet 40
Stroke in / mm 2.52” / 64mm Jet Needle 6GL67--61 / 3
Cylinders 2 Needle Jet Q--8
Piston / Cylinder Clearance
in / mm
.0045-- .0053” .11-- .13mm Throttle Gap UnderCutaway in / mm .1” 2.5mm
PistonRingEndGapin/mm
.012 -- .015” .3-- .4mm
Cutaway 2.5
Piston Marking 3021304 Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 1.5
Operating RPMr200 Fuel Screw N/A
Idle RPMr200 Pilot Air Jet N/A
Engagement RPMr300 Air Screw .75 Turns
Exhaust Valve Spring Red / White Fuel Octane 110 Octane minimum
AMBIENT TEMPERATURE
Altitude Below -30qF -30_to --10_ F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_ FAltitude Below-30F
Below -34qC
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_ C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
310
#3
300
#3
290
#3
280
#3
270
#2
260
#2
600--1200
(2000--4000)
300
#3
280
#3
270
#3
260
#3
250
#2
240
#2
1200--1800 280 270 260 240 230 2201200--1800
(4000--6000)
280
#3
270
#3
260
#3
240
#2
230
#2
220
#2
Meters
(Feet)
1800--2400
(60008000)
260 250 240 230 210 200(Feet)
(6000--8000)
260
#3
250
#3
240
#2
230
#2
210
#2
200
#2
2400--3000
(800010000)
240 230 220 210 200 190
(8000--10000)
240
#2
230
#2
220
#2
210
#2
200
#2
190
#2
3000--3700
(1000012000)
230 210 200 190 180 170
(10000--12000)
230
#2
210
#2
200
#2
190
#2
180
#2
170
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
S51H Almond/Red 7043057
66/44--.46
1943:74P
0-900
(0-3000)
S--51H Almond/Red 7043057
66/44-- .46
(70/44--.46)
19--43 : 74P
Mt
900-1800
Meters
(Feet)
900-1800
(3000-6000)
(Feet)
1800-27001800-2700
(6000-9000)
2700-37002700-3700
(9000-12000)

6. SPECIFICATIONS
1.2
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm.
Shift Weights 1321731 ( S--51H) Gearing : Chain 19 (7/8) -- 43 (3/4) : 74P
Drive Spring 7041988 Almond/Red Reverse N/A
DRIVEN CLUTCH Brake Pads 2202202
Type TEAM
BrakeType Type81
Spring 7043057
BrakeType Type81
Helix Angle
5133721 (66/44--.46 )
(70/44--.46)
CAPACITIES
BELT Fuel Tank 5Gal/19L
Belt Part Number 3211080 Oil Tank N/A PRE MIX ONLY
Belt Width (Projected)1.438” / 3.65cm. Coolant
Side Angle (Overall) 28_ Chain Case Oil
Outside Diameter 46.625” / 118.4cm. SLED DIMENSION
Center Distance 11.5” / 29.2cm.
Unit Length / Height /
Widthin/cm.
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks 7042293 / Walker Evans
StockFTS 7042294/WalkerEvans
StockIFSSpringRate 165#/in
StockFTS 7042294/WalkerEvans
StockIFSSpringRate 165#/in.
FTSSpringRate 160#/in
IFS Spring Pre--Load Installed Length
FTSSpringRate 160#/in
Front Vertical Travel 9.22” / 23cm
FTSPreLoad 80”/2cm
TRACK
FTSPre--Load .80”/2cm
Width 14”/35.5 cm
StockRTS 7042295/WalkerEvans
Length 121”/307 cm
StockRTS 7042295/WalkerEvans
Lug Height 1.75”/4.4cm Torsion Spring .374” (Sq) x 77_
TrackTension Seepage311 OptionalTorsionSpringsseepage94TrackTension See page3.11 OptionalTorsionSprings see page9.4
ELECTRICAL
Flywheel I.D. 4010629 Spark Plug / Gap RN57YCC / .025” / .70mm
CDI Marking 4010861 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see con-
versionchartonpage
12_@1750 RPMr1.5_
ElectricStart N/Aversion charton page
13.5)
[email protected]
“D” Curve
ElectricStart N/A

7. SPECIFICATIONS
1.3
MODEL: 550 PRO X..............
MODEL NUMBER: S04NX5BS.....
ENGINE MODEL: EC55PM080......
ENGINE CARBURETION
Engine Type Fuji Type
Mikuni
VM 34
Engine Displacement cc 544cc Main Jet 360280 PTO / 270 MAG
Bore in / mm 2.87” / 73mm Pilot Jet 40
Stroke in / mm 2.56” / 65mm Jet Needle 6BGY33 / 3
Cylinders 2 Needle Jet Q--2 (480)
Piston / Cylinder Clearance in / mm .004-- .0049” .090 -- .125mm Throttle Gap Under Cutaway in / mm .078” 2.0mm
PistonRingEndGapin/mm
.016 -- .021” .40 -- .55mm
Cutaway 2.0
Piston Marking N/A Valve Seat 1.5 Viton
Piston Ring Marking N Starter Jet 145
Operating RPMr200 7000 Fuel Screw 1.5 Turns
Idle RPMr200 1600 Pilot Air Jet 0.9
Air Screw N/A
Engagement RPMr300 3800
Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30qF -30_to --10_ F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_ FAltitude Below-30F
Below -34qC
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_ C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
300/290
#4
290/280
#3
280/270
#3
270/260
#3
260/250
#3
250/240
#2
600--1200
(2000--4000)
290/280
#3
270/260
#3
260/250
#3
250/240
#3
240/230
#2
230/220
#2
1200--1800 270/260 260/250 250/240 240/230 230/220 220/2101200--1800
(4000--6000)
270/260
#3
260/250
#3
250/240
#3
240/230
#2
230/220
#2
220/210
#2
Meters
(Feet)
1800--2400
(60008000)
250/240 240/230 230/220 220/210 210/200 200/190(Feet)
(6000--8000)
250/240
#3
240/230
#3
230/220
#2
220/210
#2
210/200
#1
200/190
#1
2400--3000
(800010000)
240/230 230/220 220/210 200/190 190/180 180/170
(8000--10000)
240/230
#3
230/220
#2
220/210
#2
200/190
#2
190/180
#1
180/170
#1
3000--3700
(1000012000)
220/210 210/200 200/190 190/180 180/170 170/160
(10000--12000)
220/210
#2
210/200
#2
200/190
#2
190/180
#1
180/170
#1
170/160
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1062Bushed
Dark Blue/
Red/Blue
40q
T R 2141:74P
0-900
(0-3000)
10--62 Bushed
DarkBlue/
White
Red / Blue Team Rev
Roller
21--41 : 74 P
Meters
(Feet) 900-1800
1060Bushed
Dark Blue/
Red/Blue
40q
T R 2141:74P
(Feet) 900-1800
(3000-6000)
10--60 Bushed
DarkBlue/
White
Red / Blue Team Rev
Roller
21--41 : 74 P
1800-2700
1058Bushed
Dark Blue/
Red/Blue
40q
T R 2141:74P
1800-2700
(6000-9000)
10--58 Bushed
DarkBlue/
White
Red / Blue Team Rev
Roller
21--41 : 74 P
2700-3700
1056Bushed
Dark Blue/
Red/Blue
40q
T R 1939:74P
2700-3700
(9000-12000)
10--56 Bushed
DarkBlue/
White
Red / Blue Team Rev
Roller
19--39 : 74 P

8. SPECIFICATIONS
1.4
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm.
Shift Weights 10--62 Bushed Gearing : Chain 21--41 : 74 P
Drive Spring Dark blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type TEAM
BrakeType AirCooled
Spring Red / Blue
BrakeType AirCooled
Helix Angle /
Spring Position
40_ Rev Roller
CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211078 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected)1.438” / 3.65cm. Coolant Air
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm. SLED DIMENSIONS
Center Distance 11.5” / 29.2cm.
Unit Length / Height / Widthin/cm. 110” / 48” / 46” 279 / 122 / 117 cm.
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks Nitrex / PN 7042183
StockFTS NitCell/PN7042205
StockIFSSpringRate 90/180#/in
StockFTS NitCell/PN7042205
StockIFSSpringRate 90/180#/in.
FTSSpringRate 190#/in
IFS Spring Pre--Load 2.50” / 6.4cm
FTSSpringRate 190#/in
Front Vertical Travel 9.22” / 23 cm
FTSPreLoad 230”/58cm
TRACK
FTSPre--Load 2.30”/5.8cm
Width 15” / 38 cm.
StockRTS FoxPS/PN7042184
Length 121” / 307 cm.
StockRTS FoxPS/PN7042184
Lug Height .82” / 2.08 cm. Torsion Spring .347” (Sq) x 77_
TrackTension Seepage311 OptionalTorsionSpringsseepage94TrackTension See page3.11 OptionalTorsionSprings see page9.4
ELECTRICAL
Flywheel I.D. FP9312 Spark Plug / Gap
NGK BR9ES / .028” / .70mm
CDI Marking CU7253 Voltage Regulator T1
Alternator Output 240 watts Magneto Pulses 6
Ignition Timing (see con-
versionchartonpage
27_@3000 RPMr1.5_
ElectricStart N/Aversion charton page
13.5)
[email protected]
14_@6500 RPMr1.5
ElectricStart N/A

9. SPECIFICATIONS
1.5
MODEL: 600 PRO X (PRO X@)..............
MODEL NUMBER: S04NX6ES (S04NY6ES).....
ENGINE MODEL: S2392--6044PA6E......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 38
Engine Displacement cc 599 Main Jet 440
Bore in / mm 3.04” / 77.25mm Pilot Jet 40
Stroke in / mm 2.52” / 64mm Jet Needle 9EFH1--60 / 2
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearance in / mm .00017 -- .00023” .0045 -- .0059mmThrottle Gap UnderCutaway in / mm 0.079” 2.0mm
Piston Ring End Gap in / mm .0006 -- .0008” .014 -- .020mm
Cutaway 2.0
Piston Marking 3021308 Valve Seat 1.5 Viton
Piston Ring Marking N/A Starter Jet 140
Operating RPMr200 8200 Fuel Screw 1.5
Idle RPMr200 1200 Pilot Air Jet .8
Engagement RPMr300 3500 Air Screw N/A
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30qF -30_to --10_ F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_ FAltitude Below-30F
Below -34qC
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_ C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
480
#3
460
#3
440
#2
420
#2
400
#1
390
#1
600--1200
(2000--4000)
450
#3
430
#2
410
#2
400
#1
380
#1
360
#1
1200--1800 420 400 390 370 350 330
Mt
1200--1800
(4000--6000)
420
#2
400
#2
390
#1
370
#1
350
#1
330
#1
Meters
(Feet)
1800--2400
(60008000)
400 380 360 340 330 310(Feet)
(6000--8000)
400
#2
380
#1
360
#1
340
#1
330
#1
310
#1
2400--3000
(800010000)
370 350 330 320 300 280
(8000--10000)
370
#1
350
#1
330
#1
320
#1
300
#1
280
#1
3000--3700
(1000012000)
340 330 310 290 270 260
(10000--12000)
340
#1
330
#1
310
#1
290
#1
270
#1
260
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1058
Dark Blue/
Red/Blue 584236 2339:74P
0-900
(0-3000)
10--58
DarkBlue/
White
Red / Blue 58--42--.36 23--39:74P
Mt
900-1800
1056
Dark Blue/
Red/Blue 584236 2339:74PMeters
(Feet)
900-1800
(3000-6000)
10--56
DarkBlue/
White
Red / Blue 58--42--.36 23--39:74P
(Feet)
1800-2700
1054
Dark Blue/
Red/Blue 584236 2339:74P
1800-2700
(6000-9000)
10--54
DarkBlue/
White
Red / Blue 58--42--.36 23--39:74P
2700-3700
10
Dark Blue/
Redr/Blue 584036 2339:74P
2700-3700
(9000-12000)
10
DarkBlue/
White
Red r/ Blue 58--40--.36 23--39:74P

10. SPECIFICATIONS
1.6
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm.
Shift Weights 10--58 Gearing : Chain 22--39 : 74 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Red / Blue
BrakeType LiquidCooled
Driven Helix Angle 58--42--.36 CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected)1.438” / 3.65cm. Coolant 4.5
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 325 cc
Outside Diameter 46.625” / 118.4cm. SLED DIMENSIONS
Center Distance 11.5” / 29.2cm.
Unit Length / Height /
Widthin/cm.
110” / 46” / 48” 287 / 117 / 122 cm.
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks
IFS Shocks (X2)
ARVIN / 7042215 WALKER / /7042227
FTS ARVIN / PN 7042214
Stock IFS Spring Rate 90/180#/in.(7042195) FTS (X2) WALKER / PN 7042228
FTS Spring Rate 160#/in (7041671)
IFS Spring Pre--Load
(X2)
2.0” / 5cm.
(2.75” / 7 cm.)
FTS Pre--Load 1.375” / 3.49cm
Front Vertical Travel (X2) 8.75” / 22.2 cm. (9.22” / 23.4 cm.)
FTS Pre--Load (X2) .80” / 20.3mm
TRACK RTS ARVIN / PN 7042213
Width 15” / 38 cm. RTS (X2) WALKER / PN 7042229
Length 121” / 307 cm. Torsion Spring .359” (Sq) x 77_
Lug Height 1.25” / 3.175 cm.
OptionalTorsionSpringsseepage94
Track Tension See page 3.11
OptionalTorsionSprings see page9.4
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC .028” / .70mm
CDI Marking 4010830 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see con-
24_@3500RPMr15_ ElectricStart N/A
IgnitionTiming(seecon
version chart p13.5)
[email protected]_ ElectricStart N/A

11. SPECIFICATIONS
1.7
MODEL: 700 PRO X (X@)..............
MODEL NUMBER: S04NX7CS (S04NY7CS).....
ENGINE MODEL: S2464--7070--PR7C......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc 701 Main Jet 440
Bore in / mm 3.19” / 81mm Pilot Jet 45
Stroke in / mm 2.68” / 68mm Jet Needle 9DGN5--57 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence in / mm .000187-- .0023” .00454-- .0058mmThrottle Gap UnderCutaway in / mm 0.079” 2.0 mm
Piston Ring End Gap in / mm .00047-- .00071” .012 -- .018mm
Cutaway 1.5
Piston Marking 3021307 Valve Seat 1.8
Piston Ring Marking N/A Starter Jet 145
Operating RPMr200 8000 Fuel Screw 2.25 Turns
Idle RPMr200 1400 Pilot Air Jet N/A
Engagement RPMr300 3500 Air Screw 1.25 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30qF -30_to --10_ F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_ FAltitude Below-30F
Below -34qC
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_ C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#3
440
#3
420
#3
400
#2
390
#2
600--1200
(2000--4000)
450
#3
430
#3
410
#3
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
Mt
1200--1800
(4000--6000)
420
#3
400
#3
390
#2
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(60008000)
400 380 360 340 330 310(Feet)
(6000--8000)
400
#3
380
#2
360
#2
340
#2
330
#2
310
#2
2400--3000
(800010000)
370 350 330 320 300 280
(8000--10000)
370
#2
350
#2
330
#2
320
#2
300
#2
280
#1
3000--3700
(1000012000)
340 330 310 290 270 270
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#1
270
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1062 Black/Green Black/Red 624246 2541:76P
0-900
(0-3000)
10-62 Black / Green Black / Red 62--42--.46 25--41 : 76P
Mt
900-1800
1060 Black/Green Black/Red 624246 2541:76PMeters
(Feet)
900-1800
(3000-6000)
10-60 Black / Green Black / Red 62--42--.46 25--41 : 76P
(Feet)
1800-2700
1058 Black/Green Black/Red 624246 2339:74P
1800-2700
(6000-9000)
10-58 Black / Green Black / Red 62--42--.46 23--39 : 74P
2700-3700
1056 Black/Green Black/Red 624246 2339:74P
2700-3700
(9000-12000)
10-56 Black / Green Black / Red 62--42--.46 23--39 : 74P

12. SPECIFICATIONS
1.8
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm
Shift Weights 10--62 Gearing : Chain 25--41 : 76 P
Drive Spring Black / Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Black / Red
BrakeType LiquidCooled
Helix Angle 62--42--.46 CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected)1.438” / 3.65cm Coolant 4.5 Qts / 4.26 Liters
Side Angle (Overall) 28_ Chan Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
110” / 46” / 48” 279 / 117 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks
IFS Shocks (X2)
ARVIN / PN 7042215 WALKER / PN 7042296
PRO X FTS ARVIN / PN 7042214
Stock IFS Spring Rate X2 IFS Spring Rate 80#/in. 74/165#/in.
PRO X2 FTS WALKER PN 7042228
IFS Spring Pre--Load
(X2)
3.25” / 8.2cm. (2.5” / 6.35 cm.)
FTS Spring Rate 160#/in
Front Vertical Travel8.75”/22.2cm.
PRO X FTS Pre--Load 1.375” / 3.5cm.
Front Vertical Travel (X2)
8.75/22.2cm.
9.22” / 23.4cm. PRO X2 FTS Pre--Load .8” / 2 cm.
TRACK PRO X RTS ARVIN PN / 7042213
Width 15” / 38 cm PRO X2 RTS WALKER / PN 7042229
Length 121” / 307 cm Torsion Springs .359(Sq.) 77_
Lug Height 1.25” / 3.175 cm
OptionalTorsionSpringsseepage94
Track Tension See Page 3.11
OptionalTorsionSprings see page9.4
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010839 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-18_@2750 RPMr1.5_
ElectricStart N/A
IgnitionTiming(seeconver
sion chart on page 13.5 )
[email protected]
TPS disconected
ElectricStart N/A

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14. SPECIFICATIONS
1.9
MODEL: 800 PRO X (X@)..............
MODEL NUMBER: S04NX8CS (S04NY8CS).....
ENGINE MODEL: S2470--8070--PR8C......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc 794 Main Jet 450
Bore in / mm 3.35” / 85mm Pilot Jet 55
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN5--57 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence in / mm .00023-- 00029” .0060-- .0074mm Throttle Gap UnderCutaway in / mm 0.079” 2.0 mm
Piston Ring End Gap in / mm .0006-- .0009” .016 -- .022mm
Cutaway 1.5
Piston Marking N/A Valve Seat 1.8
Piston Ring Marking 3021315 Starter Jet 135
Operating RPMr200 7900 Fuel Screw 2.0 Turns
Idle RPMr200 1500 Pilot Air Jet N/A
Engagement RPMr300 3500 Air Screw 1.0 Turns
Exhaust Valve Spring Pink/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30qF -30_to --10_ F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_ FAltitude Below-30F
Below -34qC
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_ C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
490
#4
470
#4
450
#3
430
#3
410
#3
400
#2
600--1200
(2000--4000)
460
#4
440
#3
420
#3
410
#3
390
#2
370
#2
1200--1800 430 410 400 380 360 340
Mt
1200--1800
(4000--6000)
430
#3
410
#3
400
#3
380
#2
360
#2
340
#2
Meters
(Feet)
1800--2400
(60008000)
410 390 370 350 330 320(Feet)
(6000--8000)
410
#3
390
#3
370
#2
350
#2
330
#2
320
#2
2400--3000
(800010000)
380 360 340 320 310 290
(8000--10000)
380
#3
360
#2
340
#2
320
#2
310
#2
290
#2
3000--3700
(1000012000)
350 330 320 300 280 260
(10000--12000)
350
#2
330
#2
320
#2
300
#2
280
#2
260
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1064 Black/Green Black/Red 624646 2540:76P
0-900
(0-3000)
10-64 Black/Green Black / Red 62--46--.46 25--40: 76P
Mt
900-1800
1062 Black/Green Black/Red 624246 2541:76PMeters
(Feet)
900-1800
(3000-6000)
10-62 Black/Green Black / Red 62--42--.46 25--41: 76P
(Feet)
1800-2700
1060 Black/Green Black/Red 624046 2339:74P
1800-2700
(6000-9000)
10--60 Black/Green Black / Red 62--40--.46 23--39 : 74P
2700-3700
1058 Black/Green Black/Red 624046 2339:74P
2700-3700
(9000-12000)
10--58 Black/Green Black / Red 62--40--.46 23--39 : 74P

15. SPECIFICATIONS
1.10
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm
Shift Weights 10--64 Gearing : Chain 25--40 : 76 P
Drive Spring Black / Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Black / Red
BrakeType LiquidCooled
Helix Angle 62--46--.46 CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected)1.438” / 3.65cm Coolant 4.5 Qts / 4.3 Liters
Side Angle (Overall) 28_ Chan Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
110” / 46” / 48” 279 / 117 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks
IFS Shocks (X2)
ARVIN / PN 7042215 WALKER / PN 7042296 FTS (X2) ARVIN / 7042214 WALKER / 7042297
PRO X IFS Spring Rate80#/in. FTS Spring Rate 140#/in
PRO X2 IFS Spring Rate74/165#/in. PRO X FTS Pre--Load 1.375” / 3.5 cm
IFS Spring Pre--Load (PRO X2) 3.25” / 8.26cm (2.5” / 6.35 mm)
PRO X2 FTS Pre--Load 1.25” / 3.2 cm
Front Vertical Travel (X2) 8.75” / 22cm 9.22” / 23cm
PRO X RTS ARVIN / PN 7042213
TRACK PRO X2 RTS WALKER / PN 7042298
Width 15” / 38 cm Torsion Springs .359(Sq.) 77_
Length 121” / 307 cm
Lug Height 1.25” / 3.175cm Optional Torsion Springs see page 9.4
Track Tension See Page 3.11
p pg pg
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010842 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-29_@2500 RPMr1.5_
ElectricStart N/A
IgnitionTiming(seeconver
sion chart on page 13.5 )
[email protected]
w/TPS disconnected
ElectricStart N/A