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
Piston Ring End Gap in / 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 RPM r200 Fuel Screw N/A
Idle RPM r200 Pilot Air Jet N/A
Engagement RPM r300 Air Screw .75 Turns
Exhaust Valve Spring Red / White Fuel Octane 110 Octane minimum
AMBIENT TEMPERATURE
Altitude Below -30qF -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
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 280 270 260 240 230 220
1200--1800
(4000--6000)
280
#3
270
#3
260
#3
240
#2
230
#2
220
#2
Meters
(Feet)
1800--2400
(6000 8000)
260 250 240 230 210 200
(Feet)
(6000--8000)
260
#3
250
#3
240
#2
230
#2
210
#2
200
#2
2400--3000
(8000 10000)
240 230 220 210 200 190
(8000--10000)
240
#2
230
#2
220
#2
210
#2
200
#2
190
#2
3000--3700
(10000 12000)
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 Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
S 51H Almond/Red 7043057
66/44--.46
19 43 : 74P
0-900
(0-3000)
S--51H Almond/Red 7043057
66/44--.46
(70/44--.46)
19--43 : 74P
M t
900-1800
Meters
(Feet)
900-1800
(3000-6000)
(Feet)
1800-2700
1800-2700
(6000-9000)
2700-3700
2700-3700
(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
Brake Type Type 81
Spring 7043057
Brake Type Type 81
Helix Angle
5133721 (66/44--.46 )
(70/44--.46)
CAPACITIES
BELT Fuel Tank 5 Gal/19 L
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 /
Width in / cm.
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks 7042293 / Walker Evans
Stock FTS 7042294 / Walker Evans
Stock IFS Spring Rate 165#/in
Stock FTS 7042294 / Walker Evans
Stock IFS Spring Rate 165#/in.
FTS Spring Rate 160#/in
IFS Spring Pre--Load Installed Length
FTS Spring Rate 160#/in
Front Vertical Travel 9.22” / 23cm
FTS Pre Load 80” / 2 cm
TRACK
FTS Pre--Load .80” / 2 cm
Width 14”/35.5 cm
Stock RTS 7042295 / Walker Evans
Length 121”/307 cm
Stock RTS 7042295 / Walker Evans
Lug Height 1.75”/4.4cm Torsion Spring .374” (Sq) x 77_
Track Tension See page 3 11 Optional Torsion Springs see page 9 4
Track Tension See page 3.11 Optional Torsion Springs see page 9.4
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-
version chart on page
12_@1750 RPMr1.5_ Electric Start N/A
version chart on page
13.5)
12 @1750 RPMr1.5
“D” Curve
Electric Start 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
Piston Ring End Gap in / 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 RPM r200 7000 Fuel Screw 1.5 Turns
Idle RPM r200 1600 Pilot Air Jet 0.9
Air Screw N/A
Engagement RPM r300 3800
Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30qF -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
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 270/260 260/250 250/240 240/230 230/220 220/210
1200--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
(6000 8000)
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
(8000 10000)
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
(10000 12000)
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 Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 62 Bushed
Dark Blue /
Red / Blue
40q
T R 21 41 : 74 P
0-900
(0-3000)
10--62 Bushed
Dark Blue /
White
Red / Blue Team Rev
Roller
21--41 : 74 P
Meters
(Feet) 900-1800
10 60 Bushed
Dark Blue /
Red / Blue
40q
T R 21 41 : 74 P
(Feet) 900-1800
(3000-6000)
10--60 Bushed
Dark Blue /
White
Red / Blue Team Rev
Roller
21--41 : 74 P
1800-2700
10 58 Bushed
Dark Blue /
Red / Blue
40q
T R 21 41 : 74 P
1800-2700
(6000-9000)
10--58 Bushed
Dark Blue /
White
Red / Blue Team Rev
Roller
21--41 : 74 P
2700-3700
10 56 Bushed
Dark Blue /
Red / Blue
40q
T R 19 39 : 74 P
2700-3700
(9000-12000)
10--56 Bushed
Dark Blue /
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
Brake Type Air Cooled
Spring Red / Blue
Brake Type Air Cooled
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 /
Width in / cm.
110” / 48” / 46”
279 / 122 / 117 cm.
FRONT SUSPENSION REAR SUSPENSION
Type PRO X Type PRO X
IFS Shocks Nitrex / PN 7042183
Stock FTS Nit Cell / PN 7042205
Stock IFS Spring Rate 90/180#/in
Stock FTS Nit Cell / PN 7042205
Stock IFS Spring Rate 90/180#/in.
FTS Spring Rate 190#/in
IFS Spring Pre--Load 2.50” / 6.4cm
FTS Spring Rate 190#/in
Front Vertical Travel 9.22” / 23 cm
FTS Pre Load 2 30” / 5 8cm
TRACK
FTS Pre--Load 2.30” / 5.8cm
Width 15” / 38 cm.
Stock RTS Fox PS / PN 7042184
Length 121” / 307 cm.
Stock RTS Fox PS / PN 7042184
Lug Height .82” / 2.08 cm. Torsion Spring .347” (Sq) x 77_
Track Tension See page 3 11 Optional Torsion Springs see page 9 4
Track Tension See page 3.11 Optional Torsion Springs see page 9.4
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-
version chart on page
27_@3000 RPMr1.5_ Electric Start N/A
version chart on page
13.5)
27 @3000 RPMr1.5
14_@6500 RPMr1.5
Electric Start 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 -- .0059mm
Throttle 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 RPM r200 8200 Fuel Screw 1.5
Idle RPM r200 1200 Pilot Air Jet .8
Engagement RPM r300 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 --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
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
M t
1200--1800
(4000--6000)
420
#2
400
#2
390
#1
370
#1
350
#1
330
#1
Meters
(Feet)
1800--2400
(6000 8000)
400 380 360 340 330 310
(Feet) (6000--8000)
400
#2
380
#1
360
#1
340
#1
330
#1
310
#1
2400--3000
(8000 10000)
370 350 330 320 300 280
(8000--10000)
370
#1
350
#1
330
#1
320
#1
300
#1
280
#1
3000--3700
(10000 12000)
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 Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 58
Dark Blue /
Red / Blue 58 42 36 23 39:74P
0-900
(0-3000)
10--58
Dark Blue /
White
Red / Blue 58--42--.36 23--39:74P
M t
900-1800
10 56
Dark Blue /
Red / Blue 58 42 36 23 39:74P
Meters
(Feet)
900-1800
(3000-6000)
10--56
Dark Blue /
White
Red / Blue 58--42--.36 23--39:74P
(Feet)
1800-2700
10 54
Dark Blue /
Red / Blue 58 42 36 23 39:74P
1800-2700
(6000-9000)
10--54
Dark Blue /
White
Red / Blue 58--42--.36 23--39:74P
2700-3700
10
Dark Blue /
Red r/ Blue 58 40 36 23 39:74P
2700-3700
(9000-12000)
10
Dark Blue /
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
Brake Type Liquid Cooled
Driven Spring Red / Blue
Brake Type Liquid Cooled
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 /
Width in / 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.
Optional Torsion Springs see page 9 4
Track Tension See page 3.11
Optional Torsion Springs see page 9.4
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_@3500 RPMr1 5_ Electric Start N/A
Ignition Timing(see con
version chart p13.5)
24_@3500 RPMr1.5_ Electric Start 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-- .0058mm
Throttle 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 RPM r200 8000 Fuel Screw 2.25 Turns
Idle RPM r200 1400 Pilot Air Jet N/A
Engagement RPM r300 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 --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
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
M t
1200--1800
(4000--6000)
420
#3
400
#3
390
#2
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(6000 8000)
400 380 360 340 330 310
(Feet) (6000--8000)
400
#3
380
#2
360
#2
340
#2
330
#2
310
#2
2400--3000
(8000 10000)
370 350 330 320 300 280
(8000--10000)
370
#2
350
#2
330
#2
320
#2
300
#2
280
#1
3000--3700
(10000 12000)
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 Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 62 Black / Green Black / Red 62 42 46 25 41 : 76P
0-900
(0-3000)
10-62 Black / Green Black / Red 62--42--.46 25--41 : 76P
M t
900-1800
10 60 Black / Green Black / Red 62 42 46 25 41 : 76P
Meters
(Feet)
900-1800
(3000-6000)
10-60 Black / Green Black / Red 62--42--.46 25--41 : 76P
(Feet)
1800-2700
10 58 Black / Green Black / Red 62 42 46 23 39 : 74P
1800-2700
(6000-9000)
10-58 Black / Green Black / Red 62--42--.46 23--39 : 74P
2700-3700
10 56 Black / Green Black / Red 62 42 46 23 39 : 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
Brake Type Liquid Cooled
Driven Spring Black / Red
Brake Type Liquid Cooled
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 /
Width in / 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 Travel 8.75” / 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
Optional Torsion Springs see page 9 4
Track Tension See Page 3.11
Optional Torsion Springs see page 9.4
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_ Electric Start N/A
Ignition Timing (see conver
sion chart on page 13.5 )
18 @2750 RPMr1.5
TPS disconected
Electric Start 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 RPM r200 7900 Fuel Screw 2.0 Turns
Idle RPM r200 1500 Pilot Air Jet N/A
Engagement RPM r300 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 --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
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
M t
1200--1800
(4000--6000)
430
#3
410
#3
400
#3
380
#2
360
#2
340
#2
Meters
(Feet)
1800--2400
(6000 8000)
410 390 370 350 330 320
(Feet) (6000--8000)
410
#3
390
#3
370
#2
350
#2
330
#2
320
#2
2400--3000
(8000 10000)
380 360 340 320 310 290
(8000--10000)
380
#3
360
#2
340
#2
320
#2
310
#2
290
#2
3000--3700
(10000 12000)
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 Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 64 Black/Green Black / Red 62 46 46 25 40: 76P
0-900
(0-3000)
10-64 Black/Green Black / Red 62--46--.46 25--40: 76P
M t
900-1800
10 62 Black/Green Black / Red 62 42 46 25 41: 76P
Meters
(Feet)
900-1800
(3000-6000)
10-62 Black/Green Black / Red 62--42--.46 25--41: 76P
(Feet)
1800-2700
10 60 Black/Green Black / Red 62 40 46 23 39 : 74P
1800-2700
(6000-9000)
10--60 Black/Green Black / Red 62--40--.46 23--39 : 74P
2700-3700
10 58 Black/Green Black / Red 62 40 46 23 39 : 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
Brake Type Liquid Cooled
Driven Spring Black / Red
Brake Type Liquid Cooled
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 /
Width in / 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 Rate 80#/in. FTS Spring Rate 140#/in
PRO X2 IFS Spring Rate 74/165#/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 p g p g
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_ Electric Start N/A
Ignition Timing (see conver
sion chart on page 13.5 )
29 @2500 RPMr1.5
w/TPS disconnected
Electric Start N/A