POLARIS 700 XC/SKS/RMK SLP TWIN PIPE SET P.N

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1 POLARIS 700 XC/SKS/RMK SLP TWIN PIPE SET P.N IMPORTANT: Read instruction carefully before installation. For engines with stock porting use either glass pack pipe set or canister pipe set. For ported engines use only canister pipe set. NOTE: Do not remove banding placed on the mid section of each pipe. It has been placed there to reduce noise emissions. Banding must be checked and tightened periodically. 1-Remove stock exhaust, Y-pipe, silencer, and front pipe support bracket located on inside of mag side shock tower. (Retain OEM springs for pipe installation) 2-Install the two SLP flanges marked M for mag (right) and P for PTO (left). 3-Reroute wire loom and speedo cable and cover with heat tape as shown in ILL# 1. Reposition wire loom clamp as shown. 4-Mount PTO heat shield. Using holes in the heat shield as a pilot, drill and rivet in place using 3/16" long rivets and backing washers provided.(see ILL# 1) 5-Bolt one spring clip to the chain case. (See ILL#2) Install SLP canister. Spring into place using OEM short springs. Use one SLP long spring from clip to canister. 6-Mount mag side nose cone heat shield using four 3/16" short rivets and washer provided. (See ILL# 1) Cover the mag side shock tower with five 7" pieces of insulated heat tape. Install mag pipe support bracket to mag side shock tower. Using the bottom rivet hole from the OEM pipe support rivet into place using one large head rivet. Using the bracket as a guide drill the right side hole and rivet into place using one large head rivet and backing washer. (See ILL# 1) Place the OEM rubber insulator in the hole provided on top of the mag support bracket. NOTE: The pipes can be adjusted up or down for best fit by either shaving some rubber off the top of the rubber insulator or by adding washers to the bottom of the rubber insulator. 7-Using part of the reflective heat tape (provided) cover oil pump cable in area closest to the PTO pipe. Using one plastic tie (provided) connect oil pump cable to coolant hose.(see ILL# 1) For oil pump cable clearance it maybe necessary to bend the oil pump cable adjustment tab back and re-adjust the cable. 8-Reroute choke cable using two plastic ties provided.(see ILL#2) Apply heat tape to choke cable in area closest to silencer, insure that choke cable is properly adjusted after cable is rerouted. For XC models mount one spring tab to the top of the brake housing and spring coolant hose to spring tab using one SLP long spring.(see ILL# 3) 9-A slight modification to the hood screen will be needed for hood closure clearance. A cutting template is provided in ILL. #4 that will provide adequate hood clearance on most sleds. If done correctly, this procedure is not visible with hood closed. 10-Pipe installation: Head pipes are marked with a P or M to identify MAG or PTO side location. Insure that cylinder flange seal ring end gap s are positioned 180 degrees from each other. When connecting pipe to cylinder flange be sure that seal rings do not bind. Install mag (right) pipe first (marked M ) and PTO pipe (marked P ) second. Spring into place using OEM springs. Spring mag and PTO pipe together on the inside radius of the pipe. Spring PTO pipe to the spring hook on the mag shock tower support using one SLP long spring. NOTE: Use a silicone sealer such as Loctite 598 Ultra Black on all exhaust joints. Installation Instructions Revised 8/16/02 11-Connect hood cable to hook on the top of the PTO head pipe. Reconnect cable to the next hole to the left on the hood support. 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.040 to.050 clearance between them.this is easily tested using a feeler gage. If tension is incorrect, the loop can be bent in the direction needed to increase or decrease tension. Attach vise grip firmly to the loop and bend.

2 8/16/02 CARBURETOR TUNING PAGE 2 IMPORTANT NOTE: Carb tuning specifications included in this section are a base line and should be adjusted as needed for your particular atmosphere. Use exhaust gas temperature gauges or monitoring plug and piston color for tuning guide. OIL RECOMMENDATION: For high performance trail applications SLP recommends SLP brand XPT injection oil. POLARIS 700 RMK/SKS/XC WITH SLP PIPES AND STOCK AIR BOX 0 to 3000' ELEVATION 1997 RMK/SKS/XC 1998 RMK/XC Pilot Jet 45 Jet 38 (stock) Needle R1370G clip #4 (stock XC/SKS) Needle R-1368G clip #4 (stock XC) Slide 6.5 (stock XC/SKS) Slide 6.0 (stock XC) Air Screw 1.5 Turn Air Screw 1 turn Note: Air temperatures below 10 degrees raise needle to #5 clip. 3000' & ABOVE 1997 RMK 1998 RMK 1997 SKS/XC 1998 XC Pilot jet 45 42* 45 38* Needle R1370J clip #3* CEN clip #3 R1370G clip #3* CEN clip #3 Slide 5.0 * 5.5* 6.5 * 6.0* Air screw 2 Turn 1 Turn 2 Turn 1 Turn Note: Below 0 degrees raise needle to #4 clip position. *Stock components MAIN JET ELEVATION -20 &BELOW -20 TO TO & Above ' ' ' ' Jetting Note: For engines with porting or higher than stock compression, below 3000' use Keihin needle P.N. N CCL. For ported engines, increase main jet size by ten numbers. Example 170 stock, 180 ported. Also, an altered air box, or SLP High-Flow Air Box Kit will require an increase of 2-3 main jet sizes (ie: from 170 to 175 or 178) and jet needle to be raised one clip position. For engines with porting or higher than stock compression above 3000' use Keihen needle P.N. N DEN. Choke Cable Adjustment: After choke cable is rerouted for proper pipe clearance, it is very important to check for proper adjustment. If cable is too tight, it will create a rich condition. NOTE: For best throttle response use SLP Boost Bottle P.N for twins with aftermarket heads and P.N for twins. Fuel Requirement: With present fuel quality, SLP recommends a minimum of 91 octane non-ethanol pump fuel for all snowmobiles when running at or above the specified elevation. If you want to run your sled at an elevation lower than recommended for the heads you are using, you must use a race gas/ 91 octane mixture in order to realize full power and avoid engine damage. SLP technicians can recom mend the mix ratio that will work for you. Always buy your fuel from name brand high traffic stations that have fairly new tanks. If you notice your spark plugs loosening, breaking the porcelain or changes in electrode to ground gap it probably means that you have received some low octane fuel or your timing is set incorrectly. If you are in an area where fuel quality is questionable and/or detonation symptoms are present, it is recommended to run 2 gallons of 100 octane aviation fuel or race gas to every tank.

3 8/16/02 TIMING PAGE 3 Timing Requirement: The following timing specifications have proven to be the best performance for each combination. Check timing to insure it is set to the proper recommendation. Altitude FT FT 6000 FT Plus SLP Heads with stock pipe Stock Timing Stock Timing Stock Timing SLP Heads with SLP single pipe Stock Timing Stock Timing Stock Timing SLP twin pipes w/ or w/o heads and porting 8000 Spec A 8000 Spec B 8000 Spec C Timing Model High RPM Timing Low RPM Timing Stock Spec A Spec B Spec C XC/SKS º;-1º RMK /- 1.5º XC/SKS /-1.5º RMK /- 1.5º XC/SKS /-1.5º RMK /- 1.5º XC/SKS /-1.5º RMK /- 1.5º Degree Conversion for Piston Travle, Polaris 700 Twins Degree Inches Metric Degree Inches Metric

4 8/16/02 CLUTCH TUNING POLARIS 700 XC/SKS/RMK 0' TO 3000' ELEVATION PAGE 4 Primary spring Almond/Gold P.N Primary weight P.N Secondary helix SLP P.N /42/34 or SLP Dial-A-Spring P.N /42/34 Secondary spring Silver/Blue P.N , pre load setting #2 Primary spring Almond/Gold P.N Primary weight P.N ' TO 5000' ELEVATION Secondary spring Blue P.N pre load #2 Secondary helix SLP P.N /38/34 or SLP Dial-A-Spring P.N /38/34 Primary spring SLP Black/Red P.N Primary weight P.N ' TO 9000' ELEVATION Secondary spring SLP yellow/purple P.N pre load #3 Secondary helix For best acceleration use SLP P.N /38/34 or SLP Dial-A-Spring P.N / 38/34, or for best back shift at higher elevations use SLP P.N /36 or SLP Dial-A-Spring P.N /36 Above 9000' Adjust secondary spring pre load as necessary for proper RPM. Running RPM

5 8/16/02 ILLUSTRATIONS PAGE 5 ILLUSTRATION 1 SPRING CLIP HEAT TAPE PLASTIC TIE NOSE CONE HEAT SHIELD HEAT SHIELD INSULATED HEAT TAPE REFLECTIVE HEAT TAPE 1½

6 8/16/02 ILLUSTRATIONS ILLUSTRATION 2 PLASTIC TIE PAGE 6 REFLECTIVE HEAT TAPE (CHOKE CABLE) SPRING CLIP SPRING SPRING CLIP CHAINCASE FRONT

7 8/16/02 ILLUSTRATIONS PAGE 7 ILLUSTRATION 3

8 8/16/02 ILLUSTRATIONS ILLUSTRATION 5 PAGE 8 REMOVE CORNER SECTION OF STEEL SCREEN TO ALLOW CLEARANCE FOR SLP PIPE INSTALLATION. USE TEMPLATE PROVIDED. SUGGESTED CUTTING METHODS: 1. REMOVE SCREEN FROM HOOD AND TRIM EXCESS MATERIAL WITH SHEET METAL SHEARS. 2. USE DREMEL TOOL TO CUT SCREEN FOR CLEARANCE. 3/8 FOLD LINE 1¼ 2 -½ CUT OUT THIS TEMPLATE AS A GUIDE TO TRIM THE SCREEN