Single Pipe Set with OEM Silencer for /800 RMK/XC, /800 SKS, /800 Switchback and Switchback

Transcription

1 Single Pipe Set with OEM Silencer for /800 RMK/XC, /800 SKS, /800 Switchback and Switchback P.N Important: Read instructions carefully before installation. Note: Do not remove banding placed on the mid section of each pipe. It has been placed there to reduce noise emissions, improve performance and reliability. 1-Remove stock exhaust, Y-Pipe, and silencer (Retain OEM springs and exhaust gaskets for pipe installation). Note: Use a silicone sealer such as Loctite 598 Ultra Black on all exhaust joints. 2-Install the Y-Pipe using OEM gaskets and grafoil seal. 3-Place five pieces of insulated heat tape over the top of the mag shock tower. Cover with strips of reflective heat tape. Cover the upper half of the nose cone and the right hand side of the nose cone with reflective heat tape. Cover the speedo cable from the left side hood hinge to the top of the hood. Remove the foam from the right hand side of the hood (see illustration ). Warning: Failure to position heat tape properly may result in belly pan damage. Belly pan damage due to improper installation of heat barrier tape will not be covered by Starting Line Products. 4- XC Models- Remove plastic tab on the right hand side of the sled. (see illustration ) 5- Use a silicone sealer such as Loctite 598 Ultra Black to seal silencer to the belly pan outlet hole. Install silencer and spring into place using OEM springs. 6-Install single pipe and spring into place using OEM short springs to connect the pipe to the Y- pipe and two short springs for pipe to silencer connection. Use two OEM long springs to connect the pipe to the stock pipe support bracket. NOTE: Check shock tower and hood clearance. The pipe can be adjusted up or down by removing the washer under the OEM rubber insulator or by adding one or two of the washers. NOTE: Check tightness of the clamp around the mid section of the pipe approximately every 100 miles for the first 300 miles then periodically after that. 1

2 ILLUSTRATION 1 ILLUSTRATION 2 2

3 POLARIS 700 XC/RMK SINGLE PIPE JETTING CHART Pilot Needle Needle Jet 45 (stock) RMK 55 (stock)xc 9DGJ3-57/2 (stock) RMK 9DFH10-57/3 (stock) XC P-8 (stock) Cutaway Fuel Screw Air Screw 2.0 (stock) RMK 1.5 (stock) XC Adjust as needed for best idle and throttle response Air Intake Modification: 2- Flow-Rites (P.N ) Installed in the hood. High Flow Air Horn Kit (P.N ) installed in the Air Box. Below -20º F Below -29º C -20 to +10º F -29 to -12º C +10 to +40º F -12 to +5º C Above 40º F Above 5º C MAG 580 PTO 580 MAG 560 PTO 560 MAG 540 PTO 540 MAG 500 PTO 500 MAG 490 PTO 480 MAG 470 PTO 460 MAG 450 PTO 440 MAG 400 PTO 390 MAG 350 PTO 340 MAG 380 PTO 370 MAG 340 PTO 330 MAG 330 PTO POLARIS 800 XC/RMK SINGLE PIPE JETTING CHART Pilot Needle Needle Jet 45 (stock) RMK 55 (stock)xc 9DGJ3-57/2 (stock) RMK 9DFH10-57/3 (stock) XC P-8 (stock) Cutaway Fuel Screw Air Screw 2.0 (stock) RMK 1.5 (stock) XC Adjust as needed for best idle and throttle response Air Intake Modification: 2- Flow-Rites (P.N ) Installed in the hood. High Flow Air Horn Kit (P.N ) installed in the Air Box. Below -20º F Below -29º C -20 to +10º F -29 to -12º C +10 to +40º F -12 to +5º C Above 40º F Above 5º C MAG 620 PTO 620 MAG 580 PTO 580 MAG 540 PTO 540 MAG 490 PTO 480 MAG 540 PTO 540 MAG 500 PTO 490 MAG 480 PTO 470 MAG 460 PTO 450 MAG 470 PTO 460 MAG 440 PTO 430 MAG 410 PTO 400 MAG 390 PTO 380 MAG 410 PTO 400 MAG 400 PTO 390 MAG 360 PTO 350 Important! Fuels containing ethanol or alcohol based fuel compounds will require larger main jets, usually 2 sizes larger than the jetting chart. Jet Needle must be raised one E clip position. Carburetor Tuning Note: Carb tuning specifications included in this section are a base line and should be adjusted as needed for your atmosphere. Use exhaust gas temperature guages and/or monitor piston wash as a tuning guide. 3

4 POLARIS 700 XC/RMK SINGLE PIPE JETTING CHART Below -20º F Below -29º C MAG 520N PTO 520N MAG 490 PTO 480 MAG 380 PTO 370 for stock Mikuni TM-40 Flat Slide Carbs Pilot 45 (stock) -20 to +10º F +10 to +40º F Above 40º F Needle 9DGN05-57 (stock) -29 to -12º C -12 to +5º C Above 5º C Needle Jet Stock Cutaway 1.5 (XC) MAG 510N MAG 500 MAG 490 PTO 510N PTO 500 PTO (RMK) Fuel Screw Adjust as needed Air Screw for best throttle response. MAG 470 PTO 460 MAG 400 PTO 390 MAG 450 PTO 440 MAG 340 PTO 330 MAG 350 PTO 340 MAG 330 PTO 320 Air Intake Modification: 2- Flow-Rites (P.N ) Installed in the hood. High Flow Air Horn Kit (P.N ) installed in the Air Box POLARIS 800 XC/RMK SINGLE PIPE JETTING CHART Pilot Needle Needle Jet for stock Mikuni TM-40 Flat Slide Carbs 40 (stock) XC Cutaway 1.5 (stock) XC 45 (stock) RMK 2.0 (stock) RMK 9DGN5-57 (stock) XC Fuel Screw Adjust as needed 9DGN6-57 (stock) RMK Air Screw for best idle and P-8 (stock) throttle response Air Intake Modification: 2- Flow-Rites (P.N ) Installed in the hood. High Flow Air Horn Kit (P.N ) installed in the Air Box. Below -30º F (Below -34º C) -30 to -10º F (-34 to -23º C) -10 to +10º F (-23 to -12º C) 10º to 30º F (-12 to -1º C) 30º to 50º F (-1 to 10º C) Above 50º F (Above 10º C) * Use P.N needle shim under e-clip (0-600) ( ) ( ) 520N 510N N * 470.5* * 450.5* Needle Position with E-clip and shim washer E-clip Stainless Steel shim washer (P.N ) E-clip Position Leaner Richer ( ) ,000 ( ) ,000-12,000 ( ) *Needle E-Clip set in with.020 needle shim under E-Clip. FUEL REQUIREMENT: Minimum 91 Octane fuel Important! Fuels containing ethanol or alcohol based fuel compounds will require larger main jets, usually 2 sizes larger than the jetting chart. Jet Needle must be raised one E clip position. Carburetor Tuning Note: Carb tuning specifications included in this section are a base line and should be adjusted as needed for your atmosphere. Use exhaust gas temperature guages and/or monitor piston wash as a tuning guide. 4

5 POLARIS 700 XC/RMKSINGLE PIPE CLUTCHING CHART N (Good) MTX (Best) (METERS) Black/Green (stock) MTX 2 g rivet in inner hole / / / Blue/Silver MTX / /34 MTX 1 g rivet in / / MTX 65 g P.N g rivet in / /34 w/ 1 shim Running RPM POLARIS 800 Vertical Escape Single Pipe ing Chart (159 Track) N (Good) MTX (Best) (METERS) TBA TBA TBA TBA TBA 159 Black/ Pink 0-75 MTX 58/ Black/ Pink 0-75 MTX 2 g rivet in 58/ Black/ Pink MTX No Rivets 58/ Running RPM

6 POLARIS 800 XC/RMK SINGLE PIPE CLUTCHING CHART Except Vertical Escape Specification using Button Secondary (Good Performance) N MTX (METERS) Blue/Yellow P.N g P.N No rivets 52/ / / Blue/Silver P.N g 3g rivet /36 68g 3g rivet P.N / /36 68g No rivet P.N / /36 w/ 1 shim POLARIS 800 XC/RMK SINGLE PIPE CLUTCHING CHART Except Vertical Escape Specification using MTX weights and Team Industries Roller Secondary (Best Performance) N (METERS) Blu/Red P.N MTX 71 g P.N No Rivets Red/Blu P.N P.N / ) MTX 58/40 MTX 58/40 MTX No Rivets 58/38 Running RPM

7 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. Starting Line Products 743 Iona Rd. Idaho Falls, ID Phone (208) Fax (208) web: slp@slp.cc