SLP PIPE INSTALLATION INSTRUCTIONS POLARIS 1996-97 ULTRA 680 SP SKS & RMK P.N. 09-6802 (Read instructions carefully before installation.) NOTE: The Ultra has proven to exhibit distinct personalities from one sled to another. Ultra tuning does not follow the same rules we re accustomed to. Slight variations in clutching, carburetion, RPM or gearing can result in major performance losses. Please follow the instructions carefully. NOTE: Due to the large diameter of this pipe set, some slight hood and bellypan modifications are necessary for correct installation. Modifications include: removal or modification of screen kit, removal of two screen kit mount tabs on bottom of center louvers (see illustration 8). 1. Remove stock exhaust, Y-pipe and outside rear muffler support. Disconnect silencer EGT probe from white/yellow and white/red wires. This EGT probe and the computer box is connected to a backfire safety devise for the stock silencer; it is not required for the SLP pipe set. To disable the computer, disconnect the yellow wire and the black wire leading from the computer to the three-pin plug. Do not unplug the yellow wire leading to the voltage regulator.(see ILL.# 1A) NOTE: Engine will not run properly until computer is disabled. 2. Install the three exhaust flanges included with pipe set using the OEM exhaust gaskets. (All three flanges are the same, when properly installed, flanges should have a downward angle). 3. Shock tower heat tape installation: Supplied in parts kit are eight pieces of 1 ½ x 7" tape. Place tape as shown in illustration 1. NOTE: For best tape adhesion, all surfaces must be free from dirt and oil. 4. Install mag (right) side suspension tower heat shield (small formed steel plate). Position this plate on forward edge of suspension tower 3 3/4" (see illustration 2, line C) inward from outer forward edge of suspension tower. Mark and drill 3/16" holes and fasten into place with longer small head rivets and washers provided. 5. With notched end pointing to the left, position PTO (left) side heat shield to butt up to highest portion of shock tower (see illustration 3). Mark and drill 3/16" holes. Rivet in place with longer small-head rivets. RMK models: See illustration 3 for proper heat shield location. Starting Line Products, 743 Iona Road, Idaho Falls, ID 83401 (208) 529-0244 Fax: (208) 529-9000; http://www.slp.cc 1
6. Installation of lower mag side heat shield (8"x7 ½ square aluminum plate): Position heat shield in bottom of belly pan on right side with the line of three holes pointing up toward the nose cone plate (see ILL 4). Slide heat shield between nose cone plate and belly pan, line up three holes in heat shield with holes in nose cone plate, rivet in place with short aluminum rivets provided. Using single hole at the bottom of heat shield as a guide, drill 3/16" hole in belly pan and rivet in place. (Insert this rivet from the outside of belly pan). 7. 1996 SP models: Remove the bolt connecting the steering drag link to the bellcrank. Replace the OEM bolt with the shorter 1½ x3/8 bolt and shorter lock nut provided. Insure that the bolt is installed head down. Torque to 25 ft. lbs. RMK models: Replace the OEM bolt with the allen bolt provided in the kit. Install with bolt head up, torque to 25 ft. lbs. 8. Wire loom and speedometer cable location: Remove OEM aluminum loom/cable support located at base of windshield. Route wire loom and speedo cable as shown in ILL 5, rivet OEM loom/cable support (removed from hood) to secure wire loom to left shock tower as shown in illustration. Replace OEM loom/cable support with plastic tie provided. Secure loom/cable to hood at base of windshield with plastic tie to rubber o-ring securing windshield. NOTE: Cover wire loom with reflective heat tape provided in area s closest to pipe. 9. Spring clip installation: Remove top rear chain case cover bolt. Install spring clip torque bolt to 8 ft lbs. NOTE: Small end of spring clip should point to the rear. 10. Pipe installation: Head pipes are marked to identify location. Install mag (right) pipe first (marked M), center pipe second (marked C), PTO (left) pipe third (marked P). 11. Place OEM rubber anti-vibration insulator into mount on silencer (see illustration 6) and install silencer (see illustration 7) when installing silencer into belly pan outlet plate, apply silicone to edge of silencer outlet stops as shown in illustration 8. NOTE: Make sure cylinder flange rings do not bind when installing pipes. Place ring end gaps 180 degrees from each other. For best seal apply silicone sealer (Permatex #27 B or equivalent) to all joints including silencer outlet to belly pan outlet plate connection. NOTE: If you fail to seal all voids between the silencer outlet and the belly pan outlet, exhaust gases will be forced past the pipe into the engine compartment. Symptoms are similar to an extremely over-rich condition causing fouled spark plugs and severe engine bogging, especially when riding in deep powder at slow speeds. 2
12. Spring installation: Seven short and three long springs are supplied with kit. Six short springs connect cylinder flanges to pipes, use three OEM springs for pipe to silencer connections. One long spring hooks to front of center pipe and connects to the obround hole in aluminum nose plate. Second long spring connects the center head pipe to PTO pipe middle cone section. Third long spring connects rear of silencer to spring clip on chain case. The final spring connects from front of silencer outlet to outlet plate. NOTE: Make sure the spring connecting the pipe to the aluminum nose plate is correctly installed. Without this spring in place, pipes can wear on each other and even crack. 13. Relocate right-hand hood cable mount inboard 6 inches for proper cable length. Connect hood cable to hook on center pipe. (See Illustration 9). LUBRICATION OIL INJECTION ADJUSTMENT:Set at factory recommended setting. OIL RECOMMENDATIONS: For high performance trail applications use SLP brand XPT oil. CARBUETOR TUNING 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. IMPORTANT NOTE: Due to quality variance in present day fuels, SLP recommends unleaded premium for all snowmobiles with 92 or better octane. Fuels containing alcohol or clean air additives will require larger main jets, usually two sizes more than the SLP jetting chart. Jet needle must be raised one E clip position. 3
For Ultra 680 stock engine with pipe set #09-680, air box in place, remove the two inlet rubber tubes from top inlet of air box (leave three rubber tubes in bottom of air box). Do not alter air box in any other manner. Foam inlet filters should be glued into original position. A ltitu d e M eters (F eet) 0-900 (0-3000) 900-1800 (3-6000) 1800-2700 (6-9000) 2700-3700 (9-12000) Tem p eratu re -20 & B elow -20 to +10 +10 to +40 +40 & A bove P TO 410 C enter 390 M ag 410 P TO 370 C enter 350 M ag 370 P TO 350 C enter 320 M ag 350 P TO 340 C enter 310 M ag 340 P TO 400 C enter 380 M ag 400 P TO 360 C enter 340 M ag 360 P TO 340 C enter 310 M ag 340 P TO 330 C enter 300 M ag 330 P TO 390 C enter 370 M ag 390 P TO 350 C enter 330 M ag 350 P TO 330 C enter 300 M ag 330 P TO 320 C enter 290 M ag 320 P TO 380 C enter 360 M ag 380 P TO 340 C enter 320 M ag 340 P TO 320 C enter 290 M ag 320 P TO 310 C enter 280 M ag 310 Altitude 0-3000 3-6000 6000 & higher Pilot 30 30 25 Needle SLP 14-101 SLP 14-102 SLP 14-102 Needle Jet 247-P-4 247-P8 247-P4 Air Screw ¼-½ turn 1 turn 1 turn Elevation: 0-3,000 ft. Clutch Tuning Primary Spring - Blue, Polaris part # 7041080 Primary Weight - 10 A, Polaris part # 1321589, 55 gram Secondary Spring - Blue, Polaris part # 7041296, or SLP part # 40-42 Blue Stripe #2 Preload (# 3 preload for heavy snow conditions) Helix - Progressive, 42-34, SLP part # 40-42/34 Elevation: 3-6,000 ft. Primary Spring - Blue, Polaris part # 7041080 * Primary Weight - 10 AL, Polaris part # 1321531, 53 gram Secondary Spring - Blue, Polaris part # 7041296, or SLP part # 40-42, Blue Stripe Helix - Progressive 42-34, SLP part # 40-42/34 # 2 Preload (# 3 preload for heavy snow conditions) Elevation: 6,000 & Higher Primary Spring - Black/Red, SLP part # 40-68 (best) (Second choice - Blue, Polaris part #7041080) * Primary Weight - "10", Polaris part # 1321526 (51 gram) Secondary Spring - Blue, Polaris part # 7041296, or SLP part # 40-42, Blue Stripe Helix - Progressive, 42-34, SLP part # 40-42/34 # 2 Preload (# 3 preload for heavy snow conditions) 4
Running RPM - 8700-8800 For Racing Specifications: Call SLP Tech. Line # 208-524-3397 IMPORTANT NOTES: Failure to perform the following adjustments could cause loss of performance and boggy low end power. 1. Belt side clearance. Be sure belt side clearance on drive clutch 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. 3. Tuning variable. Due to riders weight and conditions the sled is used in, heavier or lighter clutch weights and /or springs may have to be used to achieve proper running RPM. 4. Belt free play. Proper belt free play is very important for best performance. Driven shims can be added or subtracted (or cam adjustment on later models) to adjust belt as tight as possible without creeping at an idle. 5. RMK models are geared too low (20/39 std.) for most applications. We recommend gearing up to 20/37 or 20/35. Gearing Recommendations NOTE: This pipe set is designed to peak at about the same RPM as the stock Ultra. The RMK Ultra is geared for clutch lock-up at about 80 mph. Since SLP pipes are designed to peak at about the same RPM as the stock Ultra, high speed performance will not be realized unless gearing is increased. Changing to smaller axle drivers will also reduce the gear ratio and should be compensated for with an increase in sprocket ratio. 0-3000' 23/37 3-6000' 21/35 6000' & Above 20/35 5
For 1996 Ultra 680 With SLP #09-6802 Pipe Set Note: Due to present day fuels and the dramatic horsepower increase with SLP pipes, the following must be adhered to for the best performance and reliability. A. Ignition System Condition: It has been noted that on some Ultra models high RPM timing is advanced more than our recommendations. If this condition exists, piston damage can occur even with rich jetting. The following information is mandatory for proper performance and dependability. Note: Timing at low RPM will vary from one sled to another when high RPM timing is correct. This will not cause any problems as long as timing at 3500 RPM does not exceed 26º. 1. Timing Specifications: To control midrange and top end, timing must be set at 8000 RPM. Low Elevation High Elevation 12º at 8000 RPM 14º at 8000 RPM 12º =.893mm or.035 BTDC 14º = 1.213mm or.048" BTDC Timing variance ± ½º 2. Spark Plugs: a. Average Trail Riding: NGK BR9ES b. Lake Racing, High Speed Use: NGK BR10ES 6
B. Fuel System Requirements 1. Fuel Shut-Off Valve: It has been noted that this valve requires special attention when moving lever to ensure that it is fully open. It has also been noted that the fuel valve can vibrate or accidently be moved from its open position and restrict fuel flow. Fuel lines or tank vent line, if pinched or kinked, can also reduce fuel flow. Fuel flow restriction can cause piston damage or failure. 2. Fuel Octane Requirements: a. Minimum 92 octane b. RMK Model: If used under 6,000 ft. altitude, use race fuel (100 octane or better.) 3. Oxygenated Fuels: Fuels containing clean air additives, MTBE, Ethanol, Methanol, or similar materials these fuels require additional jet size and are more prone to detonation, especially on long runs at one throttle position. Increase main jet by two sizes if using these fuels C. Cylinder Head Modification: Note: Higher-than-factory-recommended compression will reduce performance and reliability. 1. Low Altitude (0 ft. to 6,000 ft.): a. SP and SKS models, DO NOT mill heads for higher compression. Even minimal milling will require use of much higher fuel octane and/or richer fuel mixture. For pump fuel, stock heads are best. b. RMK model, DO NOT mill heads. Minimum of 100 octane race gas is necessary for under 6,000 ft. altitude for stock heads. 2. High Altitude (6,000 ft. and higher): a. SP and SKS models may use RMK heads for high altitude with 92 octane fuel. Machining of SKS and SP heads to duplicate the RMK heads for high altitude use is OK, but do not mill more than.015" from head surface. For more performance and reliability, use SLP Power Dome Heads. 7
Illustrations Illustration 1 Yellow Wire Rear of Sled Voltage Regulator Do Not Disconnect Yellow Yellow (Center) Disconnect Black (Toward Front of sled) Disconnect Red/White Yellow/White Disconnect Probe Illustration 1A 8
Illustrations Line C Illustration 2 = 1 7/16 Illustration 3 9
Illustrations Illustration 4 Illustration 5 10
Illustrations Illustration 6 Illustration 7 11
Illustrations Cut Cut Illustration 8 6 Illustration 9 12
For 1997 Ultra SP Only 6 Place heat shield on left side shock tower as shown in illustration. Using heat shield as a pattern, drill two 3/16 holes in shock tower and fasten in place with provided rivets and backing washers. 13