SLP PART # ATTENTION DEALER

Transcription

1 SLP PART # ATTENTION DEALER PLEASE PROVIDE YOUR CUSTOMER WITH THE INSTALLATION AND INSTRUCTION DATA THAT IS SUPPLIED IN THIS PACKET FOR THIS PRODUCT. Before you begin, please read the following: The information contained in the instruction sheet supplied with this products is intended to provide complete setup and tuning specifications needed to have successful installation. It also acts as a reference guide for future tuning for altitude and temperature differentials. Varying from these standards can reduce performance and/or dependability. Please read the following instructions for best results. If you are experiencing difficulty after completely following the setup instructions, SLP technical assistance is available online at the SLP website: or by phone at

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3 SLP Twin Pipes for 2009 Polaris 800 RMK CFI Part # Effective Date:10/2/2008 THIS PIPE SET IS NOT RECOMMENDED FOR USE UNDER 6000 IN ELEVATION Kit Contents: 5-3/16 x 1/2 steel rivets (#090-43) 3 - short spring (#090-40) 4 - zip ties (#090-45) 1 - PTO support brace (# ) 2 - Grafoil Gaskets (# ) 3 - spring tab (# ) 3-30 reflective heat tape (#090-31) 3 - Insulated Heat Tape (#090-29) 1 - Flange (# ) 1 - Packet Anti-Seize (# ) 1 - large head rivet (#090-42) 1 - Mag Pipe (# ) 1-1/8 pipe adjustment washer (# ) 1 - PTO Pipe (# ) 2 - Rivet Washer 1 - Lightweight Silencer (# ) 1 - Mag Shock Tower Plate (# ) Important: Read instructions carefully before installation. Removal of cylinder head and cylinder is required for proper installation (see step #8). This pipe set requires a 20% 108 motor octane fuel to 91 octane premium fuel blend. Note: Do not remove banding placed on the mid section of each pipe. It has been placed there to improve performance, reliability, and reduce noise emissions. Check tightness every 100 miles for the first 300 miles and periodically thereafter. 1. Carefully remove EGT probe from pipe. Remove stock exhaust y-pipe, pipe and silencer (retain OEM springs and cylinder flange gasket for pipe installation). 2. Apply a high temp silicone sealer such as Permatex Ultra Black (PX#82180) or Loctite RTV Silicone 598, to the silencer outlet for proper seal, and spring SLP silencer into place on the stock silencer support bracket using 4 stock short springs. ILLUSTRATION #1 3. Remove insulation from the front of hood. Cover area of hood where insulation was removed with reflective heat tape (see illustration #1). Remove hood insulation and apply reflective heat tape to underside of the hood. 3

4 Hint: After removing the foam, spray carburetor cleaner on the remaining glue and allow it to sit for 60 seconds. Next, use a razor blade to lightly scrape off the glue. Clean razor blade as needed using a paper towel. Do not allow carburetor cleaner to contact other surfaces, as it can damage paint, rubber and other materials. ILLUSTRATION #2 4. On the right side of the bulkhead cross member support (see illustration #2) measure 1 up from bulkhead and 1/2 in from the front support. Drill a 3/16 hole. Rivet the spring tab into place using the large head rivet (provided) with the spring tab pointing up. 5. Remove air plenum under hood headlight by removing 5 screws that hold it into place. Cut zip ties that hold wire loom to the hood. 6. Run wire loom up the left side of hood. Remove the upper plastic rivet on hood vent. Using the three zip ties provided, fasten wire loom to hood. Use hole in the hood vent rivet hole for one of the zip ties (see illustration #3). 7. Using a razor knife notch out a 3/4 slot in the air plenum for the wire loom. Then install plenum using 5 stock screws. Cover stock wire loom hole with reflective heat tape. NOTE: At this point cylinder head and cylinder will need to be removed. (See pages 7 and 8) IMPORTANT: Cover crankcase extremely well to prevent any shavings from entering crankcase. 8. Use the PTO shock tower support as a guide put the PTO support brace on the rear portion of the aluminum shock tower on the PTO side of the sled so it goes over the existing rivets. Mark or scribe a line on the center section where you can see aluminum. Using a sander or grinder, grind to the scribe line. Place the support back into place and using it as a guide, drill out the 5 holes (using a 3/16 drill) and rivet the support into place using 5-3/16 steel rivets provided (see illustration #4). ILLUSTRATION #3 4

5 NOTE: Reinstall cylinder head and cylinder. (See pages 7 & 8) 9. Raised area on the mag side shock tower area will need to be trimmed (see illustration #5). Using a 3/16 drill bit remove the rivet at the center of the shock tower and the inside plastic dart on the back of the shock tower. Place the SLP mag shock tower bracket over the shock tower and rivet into place using the large head rivets and rivet washers provided. Silicone should be applied to the gap between the bracket and the shock tower. Cover the shock tower with insulated heat tape and cover with reflective heat tape. 10. Apply heat tape to the hood alignment tab on the belly pan just above the shock tower (see illustration #5). Use SLP PTO Shock Tower Bracket as a guide grind stock bracket and rivet into place. ILLUSTRATION #4 ILLUSTRATION #5 11. Install the SLP flange. On the top 2 bolts in the middle of the flange install spring tabs with the tab pointing up to spring from the flange to the pipes. 12. Apply the same high temp silicone sealer as used in step #2 to the pipe to silencer joint for proper seal, and install Mag pipe (without logo), springing into place with SLP short springs to secure pipe to the flange and pipe to silencer. Use an SLP medium spring to spring pipe to the spring tab installed in step #4 and use a short spring to secure pipe to stock pipe support bracket. 13. Install PTO pipe (with SLP logo) and spring into place using short springs on the head pipe, stinger and from the Mag pipe to the PTO pipe. 14. Using supplied anti-seize, coat threads of the exhaust temperature probe and install, torquing to ft/lbs. It is very important to use anti-seize, and make sure not to overtighten the probe nut. Failure to follow these guidelines can cause damage to the probe during installation. 15. Trim right hand hood vent as needed for 1/8 minimum pipe clearance. Apply heat tape to trimmed area. Trim wire loom mounting tab for 1/8 minimum clearance (see illustration #6). If pipe needs to be adjusted for belly pan or hood clearance, washers can be added or removed from the stock rubber mushroom. Apply reflective heat tape to the wire loom in the area closest to the pipe. Use the zip tie provided to tie the throttle/oil cable and coolant 5

6 overflow line for pipe clearence. 16. Remove the air box, using a 7/8 hole saw drill out 4 holes in the front of the shelf in the air box (see Illsutration #7). Remove any plastic shavings in the air box. Reinstall air box.!warning! Avoid hood and/or belly pan damage. SLP has provided the best and most practical heat protection products and installation procedures to avoid heat damage to belly pan and hood.if you are in conditions where air intake vents on the front of the hood are plugged and not allowing air flow, you must clear the vent to provide adequate cooling to engine compartment. You are responsible for heat damage to belly pan, hood or other components. ILLUSTRATION #6 ILLUSTRATION #7 This pipe set requires a 20% 108 motor octane fuel (VP C-12 recommended) to 91 octane premuim fuel blend. Any lesser octane mix will cause engine damage. SLP will not be responsible for engine damage. ECU Modification Required. For proper performance ECU must be sent to SLP for modification. See next page for additional information. For Proper Performance it is necessary to use the SLP High Flow Intake Kit: Part # which includes: High Flow Air Horn kit part # , (1) Upper Dash Intake Vents part #14-135, and Powder Snow Pre-Filter Kit part #

7 Oil Recoomendation: For best performance and dependability on the 800 be sure to run very high quality oil like Red Line full synthetic Racing oil which is the first choice. The second choice would be the new Polaris "VES Gold Plus" oil that we understand is good. No other oils are acceptable. Octane: Minimum 91 octane pump fuel. Fuels containing ethanol or oxygen carrying additives will require more fuel than non oxygen carrying fuels and may require use of an EFI Control Box. General Fuel Note: Due to inconsistencies in quality of fuel available today the following are a few tips to prevent issues that may arise due to fuel. - When riding in midrange throttle positions periodically vary throttle position, do not hold in constant position for extended periods of time. - Make sure that the premium/ethanol jumper wires are set proper for the fuel being used. - A good practice and cheap insurance is to add a 1 oz of Lucas Octane Booster to every gallon of fuel this can be found at most automotive stores. MODIFIED ECU This ECU will function with the Ethanol fuel wires. Unlike the stock connection procedure, this ECU is opposite connection and will be set for Ethanol use when the wires are connected together. Disconnect for Non Ethanol fuel use. Please install included sticker to the rear of the clutch cover. See picture below. 7

8 Courtesy of Polaris Service Manual TORQUE SPECIFICATIONS: A = 70 In.Lbs. (8Nm) B = 9 Ft.Lbs. (12 Nm) - Apply Loctite 242 C = 25 Ft.Lbs. (34 Nm) - Apply Loctite 242 D = 18 Ft.Lbs. (24 Nm) - Apply Pipe Sealant E = 168 In.Lbs. (19 Nm) - Clean and Dry F = 42 Ft.Lbs. (57Nm) NOTE: Engines with serial number beginning with S3489 Feature a bypass nozzle. Engines with serial number beginning with S3471 feature a plug. 8

9 Disassembly / Assembly Process CFI Cylinder Head / Cylinder / Pistons 1. Remove the coolant from the engine using a syphon, wet/dry vac, or drain pan. 2. Remove the air box, exhaust pipe and resonator from the engine compartment. 3. Remove the high tension wires and spark plugs from the cylinder head. 4. Remove the thermostat housing outlet cooling hose from the housing. 5. Loosen all, then remove all hea cover fasteners. Clean the fastener threads to remove any thread locking residue. 6. Discard the head cover and cylinder head o-rings. Always use new o-rings during assembly. 7. Inspect the cylinder head / combustion domes for any damage. Measure cylinder flatness. Replace cylinder head if required. 8. If only the cylinder is going to be removed, remove the fuel rail from the upper fuel injectors. See CFI Fuel Rail/Injector(s) Removal/Installation on page 4.30 in the Polaris Service Manual. 9. Loosen all, then remove the cylinder bolts. Clean the bolt threads to remove any thread locking residue. 10. Carefully pull the cylinder upwards taking care not to drop the pistons and rods abruptly against the crankcase. 11. Remove the cylinder base gasket. Use a gasket scraper to clean the gasket residue from the crankcase and cylinder base. 12. Inspect the cylinder walls. Nicasil cylinders can only be lightly honed. Damage that cannot be removed with a light hone requires cylinder replacement or re-coated. 13. Inspect the crankcase and cylinder mating surface for warping. 14. The assembly process is the reverse dissasembly. 15. Always use new gaskets asnd o-rings during assembly. Liberally coat the inside of each cylinder bore and the outside of each piston with Polaris two-stroke enigne oil. 16. When installing a piston into a cylinder, verify each piston ring opening is located at each piston ring locating pin. Squeeze the top ring, then carefully slide the cylinder over the compressed ring. Do the same with the bottom ring. 17. Follow the torque specification and torque sequences located on the previous page when tightening fasteners. 9

10 Spring Tension Adjustment: Spring loop adjustment is suggested for proper spring tension to prevent leakage and wear (low tension), allow adequate flex (proper tension) and prevent spring breakage (excessive tension). When system is installed the spring can be judged for proper tension. The winding spacing at the center of the spring will indicate tension. When proper the two center windings will have.040" to.050" clearance between them. This is easily tested with a feeler gage. If tension is incorrect, the loop on the pipe or silencer can be bent in the direction needed to increase or decrease tension. Attach a vise grip firmly to the loop and bend. SLP Twin Pipes Polaris CFI Clutching Chart Altitude (feet) ft ft Drive Clutch Running RPM Driven Clutch Clutch Spring Shift Weight Cluch Spring Driven Helix SLP Blue/Pink #40-76 SLP Blue/Pink #40-76 SLP MTX 68 g # g inner hole 2g rivet outer hole SLP MTX 68 g # g inner hole 1g rivet outer hole Black/Purple (Stock) Black/Purple (Stock) Effective /40-36 SLP P.N /38-36 SLP P.N Caring for your ceramic coated pipes and/or silencer: Ceramic Coating is an aluminum matrix applied to your exhaust system to provide a thermal barrier for more consistent performance. It is a coating which requires little maintenance to keep your pipes and/or silencer looking like new. Upon completion of new installation, wipe the ceramic coated parts of the exhaust system down with brake cleaner. This will prevent oils and grease (usually in the form of fingerprints) from burning on and staining the exhaust during first initial startup. To maintain your ceramic coated system, wash it with soap and water periodically (especially necessary after trailering it to and from your riding area on roads that have been treated with salt and other ice removing chemicals). Salt and other ice removing chemicals will attack and eat away at the ceramic coating. This will result in rust coming through the coating. Typically you will notice this rusting after your snowmobile has set for a period of time without the exhaust system being brought up to running temperature. Periodically polish your ceramic coated pipes and/or silencer after each washing with an aluminum polish such as Mothers, Maas or Blue Magic aluminum polish that can be found at any automotive parts store. Do not use any acidic cleaners! For stubborn stains use fine 000 steel wool, then use a soft cloth with polish. Failure to maintain your ceramic coated pipes or silencer can result in damage to the ceramic coating for which there is no warranty coverage. A little care will insure that your pipes and/or silencer will continue looking like new for many years. Note: In areas of the ceramic coated system where skin temperatures exceed 1300 degrees F, it is normal for the coating to turn dull gray. These areas should also be washed and polished periodically. 10