Page 1 of 6 POLARIS 1993-97 XLT 580/600 INSTALLATION INSTRUCTIONS PART #09-595 READ INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO INSTALL PIPE SET 1. Remove stock exhaust, y-pipe, front and rear muffler support. 2. Install three exhaust flanges, marked "C" for center, "P" for PTO, "M" for mag. 3. Install mag (right) side suspension tower heat shield (small formed steel plate). Position this plate on forward edge of suspension tower 2 1/2" inward from outer forward edge of suspension tower (ILL 1). Mark and drill 3/16" holes and rivet in place. 4. Position PTO (left) side heat shield as per ILL 2, mark and drill 3/16" holes. Rivet in place with small head 3/16" rivets. NOTE: For 1996 RMK models, do not use the aluminum (PTO side) heat shield. Use three 7" strips of adheasive backed insulating tape. Apply this tape to the PTO side shock tower as shown in illustration 7. To ensure best adhesion, insure that the area is clean and free from oil. 5. Wire loom and speedo cable relocation: Remove speedo cable and wire loom from instrument pod, remove aluminum wire loom clip from windshield base and re-install on left side of belly pan with 3/16" rivet (ILL 3). With 1 3/4" hole saw, open all four holes in nose plate. Re-route wire loom and speedo cable under wire loom clip on left side of belly pan, through nose plate (2nd hole form left), then up the center of the hood between louvers. Re-connect loom and cable to instrument pod. Using 1 nylon tie, secure loom and cable to windshield o-ring (left front). If louver screen kit is not installed, drill two 3/32" pilot holes in screen mount in hood. Install loom/cable support as previously stated using two screws provided. NOTE: To prevent heat damage, cover wire loom and speedo cable with reflective heat tape provided in area's closet to pipe. 6. Remove smalll coolant line at water pump inlet to check valve and replace it with longer line provided. Re-route line down and under starter housing. Secure line with tie strap provided to wire loom as per ILL 4. WARNING: WATER LINE SHOUD BE COVERED WITH REFLECTIVE HEAT TAPE IN AREA CLOSEST TO THE PIPE. 7. IMPORTANT NOTE: The bolt connecting steering drag link to bellcrank must be installed with bolt head up to allow clearance between center pipe and bolt. 8. Pipe installation: Head pipe is marked to identify location. Install mag (right) pipe first (marked "M"), center pipe second (marked "C"), and PTO (left) pipe third (marked "P"). Place OEM rubber antivibration insulator into mount on silencer (ILL 5) and install silencer (ILL 6). NOTE: On 93 and 94 model's, it may be necessary to remove.350" from end of vibro-insulator for proper hood to silencer clearence.
Page 2 of 6 NOTE: Insure that cylinder flange rings do not bind when installing pipes. Place ring end gaps 180 degrees from each other. 9. Spring installation: Seven short and two long springs are supplied with the kit. Six short springs connect cylinder flanges to pipes, one long spring hooks to the front of the center pipe and connects to the obround hole in the aluminum nose plate. One short spring connects the center head pipe to the PTO pipe mid section. Use the OEM springs for silencer to pipe connection. LUBRICATION: TUNING INSTRUCTIONS Oil Injection Adjustment: Injection arm adjustment at the full throttle position - the alignment mark should be advanced by 1-2 mm. This will allow slightly more oil delivery. Oil Recommendations: For high performance trail applications use SLP brand XPT oil. FOR XLT WITH STOCK ENGINE AND CARBS NOTE: Air box in place and unaltered. Located by the gauges on top of the hood is the air intake plate. Between the plate and hood is a piece of foam, this foam should be removed and the plate re-installed. Elevation -20 & Below -20 to +10 +10 to +40 +40 & Above 0-3000' 250 240 230 220 3-6000' 230 220 210 200 6-9000' 210 200 190 180* 9-12000' 190 180 170* 160* *Marked altitudes should drop Jet Needle on position (raise E clip). MAIN JET NOTE: MAG CYLINDER ON SOME SLEDS (MOST COMMON ON 1993 MODELS) REQUIRES ONE SIZE LARGER MAIN JET THAN THE ABOVE CHART. PLUG COLOR WILL BE EVEN ON EACH CYLINDER WHEN CORRECT. Pilot Jet - 0-5000 ft: #35, 5000 ft. & Higher: #35 Needle Jet - 0-5000 ft: #166-Q2 (stock), 5000 ft. & Higher: #166-Q0 Jet Needle - 6DP17-3 (stock), 95 XLT 600 6DH17-3 (stock) Slide Cut Away - 2.0 (stock) TRAIL PORTED ENGINES: XLT with SLP trail porting, stock 34 mm carbs and SLP pipes. Use the above tuning chart and increase main jet size by one and richen needle clip by one position.
Page 3 of 6 FOR XLT 580 WITH STOCK ENGINE WITH 38 mm ROUND SLIDE CARBS NOTE: Air box in place and unaltered. Located by the gauges on top of the hood is the air intake plate. Between the plate and hood is a piece of foam, this foam should be removed and the plate re-installed. Elevation -20 & Below -20 to +10 +10 to +40 +40 & Above 0-3000' 290 280 270 260 3-6000' 270 260 250 240 6-9000' 240 230 220 210 9-12000' 220 210 200 190 MAIN JET NOTE: MAG CYLINDER ON SOME SLEDS (MOST COMMON ON 1993 MODELS) REQUIRES ONE SIZE LARGER MAIN JET THAN THE ABOVE CHART. PLUG COLOR WILL BE EVEN ON EACH CYLINDER WHEN CORRECT. Pilot Jet - #45 Needle Jet - 0-5000 ft: 247 Q-0, 5000 ft. & Higher: 247 P-8 Jet Needle - 6DP10-3 Slide Cut Away - 2.5 Air Screw - 1.5 turn BORED 38 mm ROUND SLIDE CARBS TO 39.2 mm: Increase Main Jet by One size over the above chart. FOR 1996 XLT RMK WITH ACCS -20 & Below -20 to +10 +10 to +40 +40 & Above 220 210 190 180 Pilot Jet - #35 Needle Jet - 480 Q-0 Jet Needle - 6DP17-3
Page 4 of 6 FOR 1997 XLT RMK WITH ACCS -20 & Below -20 to +10 +10 to +40 +40 & Above 280 260 240 230 Pilot Jet - #50 Needle Jet - 480 P-2 Jet Needle - 6EJ3-2 Air Screw - 3/4 turn Running RPM - 8900-9100 Elevation: 0-3000 ft. Primary Spring - Blue, #7041080 Primary Weight - 10M White, #5630369 Secondary Spring - Red, #3 hole Helix - Stock (*) Elevation: 3-6000 ft. Primary Spring - Blue, #7041080 Primary Weight - 10M Red, #5630325 Secondary Spring - Red, #3 hole Helix - Stock (*) Elevation: 6000 ft. & Above Primary Spring - Gold, #7041148 Primary Weight - P-1 w/ 40-4 Max clips, #5630089 Secondary Spring - Red, #3 hole Helix - Stock (*) CLUTCH TUNING FOR XLT 580/600 WITH SLP PIPE SET (*) Optional Multi-Angle Helix: May be used for additional acceleration. 0-3000 ft. altitude, use a 40/36, SLP #40-40/36. For 3000 and higher altitude, use a 38/34 helix, SLP #40-38/34. With all multiangle helixes the SLP #40-3 Black driven spring must be used. The 40-3 Black spring will also improve performance with the stock helix. IMPORTANT NOTES: Failure to perform the following adjustments could cause loss of performance and ''boggy'' low end power. 1. Belt side clearance. Be sure the belt side clearance is not excessive. Recommended.010" to.030" between belt and clutch face. Re-shim spider if needed. Excessive clearance may cause a low end bog. 2. Type of belt. Use only SLP-approved performance belts or stock Polaris brand belts.
Page 5 of 6 3. Belt free-play. Proper belt free-play is very important. To achieve best performance, driven shims can be added or subtracted (or cam cam adjust tightened) to adjust belt as tight as possible without creeping at an idle. 4. Gearing. We do not recommend gearing lower than 19/39 with the above clutch specs. If lower gearing must be used, it will be necessary to increase the weight of the primary cam arms. IGNITION TIMING Ignition timing should be checked for best performance. Timing should be 20 degrees at 7500 RPM, 28 degrees at 3000 RPM ± 1 degree. High RPM timing is most important. Refer to Polaris service information for proper timing procedure. ILLUSTRATIONS
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