I CHAPTER 5 FUEL SYSTEM CARBURETION

I CHAPTER 5 FUEL SYSTEM CARBURETION
CHAPTER 5
FUEL SYSTEM I CARBURETION
Jet Part Numbers ................... .. .... .... 5.1 - 5.1 a
1996 Condensed Data .......... . .. . . . . .... .. . 5.2- 5.3
1997 Condensed Data ... ... .......... .. ...... 5.3a- 5.3b
1998 Condensed Data ... . .... . ......... . ..... 5.3c
Exploded View- Keihin ................... .... . 5.3d
Exploded View - VM30SS . . . ... ..... . .. . .. .... 5.4
Exploded View - VM34SS . . . . . . . . . . . . . . . . . . . . . 5.5
Exploded View- VM38SS ......... . .... . ...... 5.6
Exploded View- VM34SS with ACCS ........... 5.7
1996 Jetting Compensation Charts ....... . .... .. 5.8 - 5.15
1997 Jetting Compensation Charts . . . . . . . . . . . . . . 5.15a - 5.15j
1998 Jetting Compensation Charts . . . . . . . . . . . . . . 5.15k - 5.15p
Gasoline Volatility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Systems .. ..... .. .... ... . .. . . .... .. . ..... . ... 5.17-5.23
Component Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5.24-5.27
Component Effect vs Th rottle Opening .... ... ... 5.28
Jetting Guidelines ..... . . .. . ..... . ... . ........ 5.29
Oxygenated Fuel - Carbureted Models . .... . .... 5.30
Oxygenated Fuel- EFI Models ... . ......... . .. . 5.31
ACCS System ......... . ......... . ....... .... . 5.32-5.34
Mikuni Carburetor Service . ...... .. . . .......... 5.35-5.37
Mikuni Carburetor Float Level I Adjustment ...... 5.38
Keihin Carburetor Service ...... . ...... . ..... .. 5.38a-5.38e
1996 Synchronization Specs .. . .. . ........... . . 5.38f
1997 Synchronization Specs
5.39
1998 Synchronization Specs . . .. .. ... ...... . ... 5.39a
Synchronization Procedure . . . . . . . . . . . . . . . . . . . . 5.39b-5.39c
Choke Adjustment (All) ........................ 5.40
Fuel Pump Operation .. . . . ........ . ......... . . 5.42-5.45
Water Trap Service ..... . . . .......... . .... . ... 5.46
Troubleshooting ........... . ... . .. . ........... 5.47-5.48
FUEL SYSTEM/CARBURETION
Jet Part Numbers
Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.
A
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
'-
A
A
A
A
A
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
A
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where refueli ng is performed or where
gasoline is stored or used.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
Jet Part Numbers
The following chart lists all Mikuni main and pilot jets and the part number of each that are presently available.
Mikuni
Mikuni
PILOT JET NO PART NO.
25 .... .. ... .. . . 3130064
30 ...•......... 3130065
35 . . . .... .. .. .. 3130066
40 . . .... . ... ... 3130067
45 ............. 3130068
PILOT JET NO
50
55
60
65
Mikuni
HEX HEAD
MAIN JET NO.
PART NO.
80 ............. 3130099
85 ........... .. 3130100
90 ............. 3130101
95 . .. .. ....... 3130102
100 ............ 3130103
105 ............ 3130104
110 ..... . ... ... 3130105
115 ............ 3130106
120 ............ 3130107
125 . . . . ..... .. 3130108
130 ............ 3130109
135 .... . .. ..... 3130110
140 ..... . ...... 3130111
145 ..... ..... . . 3130112
150 ..... . .. .. . . 3130113
155 ............ 3130114
160 ............ 3130115
165 ............ 3130116
170 ............ 3130117
175 ............ 3130118
180 ............ 3130119
185 ........... . 3130120
190 .......... 3130121
195 ............ 3130122
200 ............ 3130123
210 . ........ . 3130124
220 ....... .. ... 3130125
230 ............ 3130126
240 ....... . .... 3130127
Polaris Industries Inc.
Keihin
PART NO,
3130069
3130070
3130071
3130072
PILOT JET
35 .. ...
38 .....
40 . ... .
42 .. . ..
45 .....
48 .....
Mikuni
Keihin
PARI NO
3050219-35
3050219-38
3050219-40
3050219-42
3050219-45
3050219-48
PILOT JET
50 .....
52 . . . . .
55 .....
58 .....
60 .....
62 . ... .
65
PART NO
3050219-50
3050219-52
3050219-55
3050219-58
3050219-60
3050219-62
30502 19-65
Keihin
HEX HEAD
MAIN JET NO
PART NO.
250 ............ 3130128
260 ............ 3130129
270 ............ 3130130
280 ............ 3130131
290 ........ . ... 3130132
300 .... •. ...... 3130133
310 ........... 3130134
320 .... . .... . .. 3130135
330 ....... ..... 3130136
340 .... . ....... 3130137
350 ... ......... 3130138
360 . .......... . 3130139
370 ....... ..... 3130290
380 ........ .... 3130140
390 .. .. ....... 3130480
400 ........... 3130141
410 ......... . .. 3130599
420 ... .. ... .. . . 3130142
430 ........ .. . . 3130143
440 ............ 3130144
450 ............ 3130145
460 ... ... ... . . . 3130146
470 .. .. . .. .. 3130147
490 .....•...... 3130148
500 ............ 3130149
530 . .......... 3130150
560 ... ... .. ... . 3130151
590 . ... .. ...... 3130152
620 . .. .... . .... 3130153
5.1
Long Hex Head (Amal Type)
MAIN JET NO PART NO,
140 ......... 3050235-140
142 ......... 3050235-142
145 ..... • ... 3050235-145
148 ...... . .. 3050235-148
150 ......... 3050235-150
152 . . . . . . . . . 3050235-1 52
155 ......... 3050235-155
158 . . . . . . . . . 3050235-158
160 . . . . . . . . . 3050235-160
162 . .. . ... . . 3050235-162
165 . ..... . .. 3050235-165
168 . . . . . . . . . 3050235-168
170 . ..... ... 3050235-170
172 ......... 3050235-172
176 ........ . 3050235-176
178 . ........ 3050235-178
180 ......... 3050235-180
182 ......... 3050235-182
185 . . .. . . . .. 3050235-185
188 .. . .. .. .. 3050235-1 88
190 .. . . .. .. . 3050235-190
192 . . . . . . . . . 3050235-192
195 .. .. .. .. . 3050235-195
198 . .. ... . .. 3050235-198
200 . . . . . . . . . 3050235-200
205 . . . . . . . . . 3050235-205
210 .. .. .. ... 3050235-210
215 . ........ 3050235-215
220 .. ' . . . . . . 3050235-220
9/97
FUEL SYSTEM/CARBURETION
Jet Part Numbers
Jet Needle Part Numbers (Mikuni)
JET NEEDLE NO.
5DP7 ......... . .
5DT49 .. . .......
5DP10 . .. .... ...
5DP10 .... . .. .. .
5DT2 ........ .. .
5D78 " ..... " "
5F81 .......... ..
5D78 " ..... " "
6CEY6 . . . . . . . . . .
6CGY3 . . . . . . . . . .
6CGY6 .........
6DH3 .......... .
PART NO.
3130155
3130154
3130333
3130310
3130473
31 30667
3130528
3 130667
3130476
31 30484
3130652
3130470
JET NEEDLE NO.
6DH4 .. . . .. ... .. . .. ..
6DH5 . ... . ...........
6DH7 ............... .
6DH8 .. .. .. . .. .. . .. ..
6DH29 .. .. . . . .. . . . . ..
6DP1 . . ... .. ... . .. . ..
6DP17 ... .. .... . .. ...
6EJ26 .... . .... . .... .
6EJ3 . .. .. . . .. . . .. .. .
6F4 ... .. . .. ..... ....
6F9 . . . . .. . . . .. . . ... .
PART NO.
3130402
3130391
3130329
3130645
3130462
3130156
3130374
3130423
3130680
3130319
3130378
JET NEEDLE NO.
R-1369G .. . .. .. .. . . ..
R-1370J . . .. . ........
R-1371J .. . .. .. ......
PART NO
3050245
3050221
3050246
NEEDLE JET NO
P-6 (247) ........ ... ..
P-8 (247) ......... .. ..
0·0 (247) .... . .. " . . .
Q-2 (247) . . ... ... . .. .
Q-4 (247) ... . .. . . . . "
Q-8 (247) ....... ' ....
R·O (247) ...... . . . ...
P-0 (286) .............
P-2 (286) . . . . . . . • . . .
0-4 (286) . .... ... ....
0 -6 (480) ...•. . ..•...
0-8 (480) ... " ... . " .
P-2 (480) .............
P-4 (480) ..........
Q-6 (480) " .... " " "
P- 8 (513) ...........
PART NO.
3130655
3130382
3130414
3130165
3130603
3130485
3130477
3130607
3130608
3130635
3130429
3130683
3130675
3130639
3130618
3130510
Jet Needle Part Numbers (Keihin)
JET NEEQLE NO.
R-1368G .. .. . ..
R-1370G . . . . . . . .
R-1371 G . . . . . . . .
R-1372J ... .. ..
PART NO
3050244
3050220
3050256
3050247
Needle Jet Part Numbers (Mikuni)
NEEDLE JET NO
P-4 (159) ...... .
P-2 (166) .... .. ..
P-4 (166) .. .... ..
P-4 (166) . ..... . .
P-6 (166) .. .. .. .
P-8 (166) .. . .. ..
Q-2 (166) .... " ..
0 -4 (169) " . " ..
0 -4 (169) " .. "
0-6 (169) ... " .. .
0-6 (169) ..... . . .
0-8 (169)" • " ..
0-8 (171) .... ..
P-0 (225) ... . .. ..
P-2 (255) .. .. .. .
P-2 (259}
P-0 (247) .......
P-2 (247) .. .. ..
P-4 (247) ........
PART NO.
3130162
3130460
3130348
3130499
3130160
3130421
3130376
3130166
3130409
3130358
3130469
3130453
3130035
3130579
3130608
3130161
3130671
3130672
3130641
Throttle Valve Part Numbers (Keihin)
Throttle Valve No.
3.0 . ".. . ...
4.0 .....•.....
5.0 ...... ' ... .
5.5 . . .. ". ".
6.0 .......... .
6.5
7.0 .
7.5
8.0
9.0
9/97
PART NO.
3050234·802
3050234-C02
3050234·D02
3050234-J02
3050234·E02
3050234·K02
3050234-F02
3050234-L02
3050234-G02
3050234-H02
5. 1a
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1996 Condensed Data
Engine
Model
Cyl.
Disp.
CCs
Carburetor
Model, Mount
Type & No.
Std. Main Jet
&Type
Std.
Pilot
Jet
Air Screw Adjust
(counterclockwise from light
seat)
Fuel
Octane
Reqmt.
EC34-2PM(E)02
339
VM30SS (2)
Zinc
145 Hex
35
1 1/2 Turn
87'
Indy Sport/Sport Touring/
TranSport
EC44-3PM01
432
VM34SS (2)
Zinc
180 Hex
35
1 1/4 Turn
87'
Indy Super Sport
EC44·3PM02
432
VM34SS (2)
Zinc
180 Hex
35
1 1/4 Turn
87'
Indy 440 LC
EC45PL06
432
VM34SS (2)
Zinc
260 Hex
40
1 1/2 Turn
87'
Indy 440 XCR
EC45PL07
439
VM34SS (2)
Aluminum
260 Hex
50
1 Turn
91
Indy 440 XCR SP
EC45PL08
439
VM34SS (2)
Aluminum
260 Hex
50
1 Turn
91
Indy Trail/Touring
EC50PM(E)04
488
VM34SS (2)
Z1nc
220 Hex
35
1 Turn
87'
Indy Classic
EC50PLE11
488
VM38SS {2)
Aluminum
340 Hex
40
1 Turn
87'
Indy Classic Touring
EC50PL14
488
VM34SS (2)
Zinc
240 Hex
40
3/4 Turn
87'
Indy WideTrak GT
EC50PM03
488
VM34SS (2)
Zinc
200 Hex
30
1 Turn
87'
Indy WideTrak LX
EC50PL12
488
VM34SS (2)
Zinc
190 Hex
35
3/4 Turn
87'
Indy 500/SKS
EC50PL11
488
VM38SS (2)
Aluminum
340 Hex
40
1 Turn
87'
lndySOO RMK
EC50PL15
488
VM38SS (2)
Aluminum
240 Hex
45
1 Turn
87'
Indy XLT/SKS
EC58PL03
597
VM34SS {3)
Z1nc
210 Hex
35
1 Turn
87'
EC58PLE05
597
VM34SS (3)
Zinc
250 Hex
35
1 Tum
87'
Indy XLT RMK w/ACCS
EC58PL07
597
VM34SS (3)
Zinc
190 Hex
35
N/A
(see page 5.32)
87'
Indy XLT SP/600 XCR
EC58PL02
597
VM38AL (3)
Aluminum
260 Hex
35
1 Turn
91
Indy 600 XCR SP
EC59PL01
598
VM38SS (3)
Aluminum
400 Hex
40
1 1/2 Turn
91
Indy Ultra SP/SKS
EC68PL01
679
VM38AL (3)
Alumi num
340 Hex
50
1 Turn
87'
Indy Ultra RMK
EC68PL04
679
VM38AL (3)
Alummum
280 Hex
50
1 Turn
87'
Indy Storm AMK
EC80PL04
794
VM38 (3)
Alummum
PTO Ctr Mag
330 330 350
45
1 Turn
91
Indy Storm/SKS
EC80PL05
794
VM38 (3)
Al umi num
PTO Ctr Mag
400 400 420
45
1 Turn
91
Machine
Model
Indy Ute/GT/Deluxe
Indy XLT Touring
,
• Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89.
9/97
5.2
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1996 Condensed Data
Engine
Model
Jet Needle No.
UE" Clip
Position
Needle
Jet No.
Throttle
Valve
Cutaway
Valve
Seat
EC34-2PM02
5DP7-2
EC44-3PM01
0-6 (169)
2.5AL
1.5
1600
Variable Ratio
Auto Injection
6DH7-3
P-4 (166)
2.5CH
1.5
1600
Variable Ratio
Auto Injection
EC44-3PM02
6FJ6-3
P-8 (166)
2.0
1.5
1600
Variable Ratio
Auto Injection
EC45PL02
6DH7-3
P-2 (480)
2.0
1.5
1600
Variable Ratio
Auto Injection
EC45PL07
6DH3-2
0-4 (286)
2.0
1.5
1800
Variable Ratio
Auto Injection
EC45PL08
6DH3-3
0-4 (286)
2.0
1.5
2000
Variable Ratio
Auto Injection
EC50PLE11
6F9-3
P-8 (247)
2.5
1.5
1900
Variable Ratio
Auto Injection
EC50PL14
6EJ26-2
P-4 (480)
3.0CH
1.5
1600
Variable Ratio
Auto Injection
EC50PME04
6DH7-3
P-8 (166)
3.0
1.5
1600
Variable Ratio
Auto Injection
EC50PM03
6DH7-3
P-6 (166)
3.0CH
1.5
1600
Variable Ratio
Auto Injection
EC50PL12
6EJ26-2
P-6 (166)
3.0CH
1.5
1600
Variable Ratio
Auto Injection
EC50PL11
6F9-3
P-8 (247)
2.5CH
1.5
1600
Variable Ratio
Auto Injection
EC50PL15
6F9-2
P-4 (247)
2.0
1.5
1600
Variable Ratio
Auto Injection
EC58PL03
6DP17-3
Q-2 (166)
2.0
1.5
1700
Variable Ratio
Auto Injection
EC58PLE05
6DP17-3
Q-2 (166)
2.5
1.5
1700
Variable Ratio
Auto Injection
EC58PL07
6DP17-3
Q-6 (480)
2.0
1.5
1700
Variable Ratio
Auto Injection
EC58PL02
6DH7-3
Q-2 (247)
2.5CH
1.5
2000
Variable Ratio
Auto Injection
EC59PL01
6CEY6-3
R-0 (247)
2.5
1.5
2000
Variable Ratio
Auto Injection
EC68PL01
6DH8-2
P-4 (247)
2.0
1.5
1800
Variable Ratio
Auto Injection
EC68PL04
6DH8-2
P-4 (247)
1.5
1.5
1800
Variable Fatio
Auto Injection
EC80PL04
6CGY6-3
P-6 (247)
3.0
1.5
1600
Variable Ratio
Auto Injection
EC80PL05
6CGY6-3
Q-0 (247)
3.0
1.5
1600
Variable Ratio
Auto Injection
Polaris Industries Inc.
·'
5.3
Idle
RPM
Fuel/Oil
Mixture
± 200
11/95
FUEL SYSTEM/CARBURETION
1997 Condensed Data
Engine
Model
Cyl.
Dlsp.
ccs
Carburetor
Model, Mount
Type & No.
Std. Main Jet
& Type
Std.
Pilot
Jet
Air Screw Adjust
(counterclockwise from light
seat)
Fuel
Octane
Reqmt.
EC34-2PM(E)02
339
VM30SS (2)Zinc
150 Hex
35
1 1/2 Turn
87'
Indy Sport/Sport Touring/
TranSport
EC44-3PM02
432
VM34SS (2)Zinc
185 Hex
35
1 Turn
87"
Indy XCF
Machine
Model
Indy Ute/GT/Deluxe
EC44-3PM02
432
VM34SS (2)Zinc
185 Hex
35
1 Turn
87"
Indy Super Sport
EC50PM06
488
VM34SS (2)Zinc
250 Hex
45
1 Turn
87'
Indy Trail/Touring
EC50PM(E)04
488
VM34SS (2)Zinc
230 Hex
35
1 1/2 Turn
87'
Indy Trail RMK
EC50PM05
488
VM34SS (2)Zinc
(ACCS)
270 Hex
45
1 Turn
87'
Indy 440 LC
EC45PL09
432
VM34SS (2)Zinc
270 Hex
40
3/4 Turn
87'
lndy440 XC
EC45PL08
438
VM34SS (2) AL
240 Hex
50
3/4 Turn
87'
Indy 500/SKS/Ciasslc
EC50PL17
488
VM38SS (2) AL
350 Hex
40
1 Tum
87'
Indy 500 RMK
EC50Pl16
488
VM34SS (2)Zinc
(ACCS)
250 Hex
40
3/4 Turn
87'
Indy Classic Touring
EC50PL 19
488
VM34SS (2)Zinc
250 Hex
40
1 Turn
87'
Indy WideTrak GT
EC50PM03
488
VM34SS (2)Zinc
200 Hex
30
1 Turn
87'
Indy WideTrak LX
EC50PL20
488
VM34SS (2)Zinc
195 Hex
35
1/2 Turn
87"
Indy XLT/SKS
EC58PL03
597
VM34SS (3)Zinc
220 Hex
35
1 Turn
87"
lndyXLT AMK
EC58PL07
597
VM34SS (3)Zinc
(ACCS)
240 Hex
50
3/4 Turn
87"
EC58PL(E)09
597
VM34CS (3)Zinc
260 Hex
35
1 Turn
87"
Indy XLT SP
EC58PL12
597
VM38AL (3) AL
270 Hex
35
1.5 Turn
87"
Indy XLT LTD SP
EC58PL12
597
VM38AL (3) AL
310 Hex
35
1 Turn
87'
Indy 600 XC
EC58PL08
597
VM38SS (3)Zinc
270 Hex
35
3/4 Turn
87"
Indy 600 XCRISE
EC59PL01
598
VM38SS (3) AL
PTOCtrMag
360 380 380Hex
40
1/2 Turn
91
Indy Ultra/SP/Touring
EC68PL01
679
VM38AL (3) AL
340 Hex
40
1 Turn
87'
Indy Ultra SPX/SE
EC68PL03
679
VM38AL (3) AL
380 Hex
50
1 Tum
91
lndy700 SKS
SN?OLSDCSP-0 1
701
PWK 39-Keihin
185 Long Hex
40
1 Turn
87'
lndy700 RMK
SN?OLCDCSP-02
701
PWK 39-Keihin
158 Long Hex
55
1/2 Turn
87"
Indy Storm RMK
EC80PL04
794
VM38SS (3) AL
PTOC!rMag
300 290 310
55
1 Turn
91
Indy Storm/SE
EC80PL05
794
VM38SS (3) AL
PTO CtrMag
410400420
50
1 Turn
91
Indy XLTTouring/LTD
~
Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89.
9/96
5.3a
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1997 Condensed Data
Engine
Model
Jet Needle No.
"E" Clip
Position
Needle
Jet No.
Throttle
Valve
Cutaway
EC34-2PM02
50P7-2
0 -6 (169)
2.5
EC44-3PM02
6FJ6-3
P-8 (166)
2.0
EC45PL09
60H7-2
P-2 (480)
2.0
EC45PL08
6DH3-3
0-4 (286)
1.5
EC50PM03
6DH7-3
P-6 (266)
3.0
EC50PM04
60H7-3
P-8 (166)
3.0
EC50PM05
6DH7-2
P-2 (480)
2.0
EC50PM06
6DH7-3
0-8(480)
2.0
EC50PL16
6EJ26-3
P-2 (480)
2.5
EC50PL17
6F9-3
P-8 (247)
2.5
EC50PL19
6EJ26-3
P-2 (480)
3.0
EC50PL20
6EJ26-2
P-6 (166)
3.0
EC58PL03
6DP17-3
Q-2 (166)
2.0
EC58PL07
6EJ3-2
P-2 (480)
2.0
EC58PL08
6D H7-3
Q-2 (247)
2.0
EC58PL09
60P17-3
Q-2 (166)
2.5
EC58PL12
60H7-3
Q-2 (24 7)
2.0
EC59PL01
6CEY6-4
P-6 (247)
2.0
EC68PL01
6DH8-2
P-4 (247)
2.0
EC68PL03
6CEY6-4
Q-2 (247)
3.0
SN70LCDCSP-01
R1370G-3
Fixed
6.5
SN70LCDCSP-02
R1370J-3
Fixed
5.0
EC80PL04
6CGY6-3
P-6 (247)
2.5
EC80PL05
6CGY6-3
Q-0 (247)
3.0
Polaris Industries Inc.
5.3b
9/96
FUEL SYSTEM/CARBURETION
1998 Condensed Data Machine
Model
Engine
Model
Cyl.
Disp.
CCs
Carburetor
Model, Mount Type
& No.
Std. Main Jet
& Type
Std.
Pilot
Jet
Air
Screw
(Turns
Out)
Fuel
Octane
Reqmt.
Jet
Needle
Needle
Jet#
Throt.
Valve
Cutaway
&
ECiip
Indy Lite/
Lite Deluxe/
Lite Touring
EC34-2PM02A
339
VM30SS (2)Ztnc
150 Hex
35
1 1/2
87"
5DP7
#2
0-6
(169)
2.5 AL
Indy Sport/
Sport Touring/
TranSport, XCF
EC44-3PM024
432
VM34SS (2)Zinc
185 Hex
35
1
87'
6FJ6
#3
P-8
(166)
2.0
Indy Super Sport
ECSO PM061
488
VM34SS (2)Zinc
250 Hex
45
1
87'
6DH7
#3
0-8
(480)
2.0
Indy Trail/Touring
ECSOPM043
488
VM34SS (2)Zinc
230 Hex
40
1
87'
6DH7
#3
P-8
(166)
3.0
Indy Trail RMK
ECSOPM051
488
VM34 (2)Zinc
(ACCS)
270 Hex
45
1
87"
6EJ3
#3
0-6
(480)
2.0
Indy 440 LC
EC45PL091
432
VM34SS (2)Zinc
270 Hex
40
3/4
87"
6DH7
#2
P-2
{480)
2.0
SN44-44LCDCSP01
438
VM34SS
360 Hex
45
1 1/2
87'
6DH7
#3
P-4
(286)
2.0
Indy 500/
500 Classic
ECSOPL 171
488
VM38SS (2) AL
350 Hex
45
3/4
8r
6F9
#3
P-6
(480)
2.5
Indy 500 RMK
ECSOPL161
488
VM34SS (2)Zinc
(ACCS)
260 Hex
55
1 1/4
8r
6FJ43
#2
P-0
(480)
2.5
Indy Classic Tmg
EC50PL191
488
VM34SS (2)Zinc
250 Hex
40
3/4
87'
6EJ26
113
P-2
(480)
3.0
Indy WideTrak LX
ECSOPL201
488
VM34SS (2)Zinc
195 Hex
35
1/2
87'
6EJ26
112
P-6
(166)
3.0
Indy XLT LTD/
XLT Touring
EC58PL130
597
VM34SS (3)Ztnc
240 Hex
40
1
87'
6DP17
113
Q-4
(480)
2.5
Indy XLT SP
EC58PL140
597
VM38SS (3)AL
330 Hex
35
1.5
87'
6DH7
#3
Q-0
(247)
2.0
Indy XLT Classic
EC58PL150
597
VM38SS (3)AL
340 Hex
35
1.5
87'
6DH7
113
Q-0
(247)
2.0
lndy600 XCR
EC59PL020
598
VM38SS (3) AL
PTOCtr Mag
40
1/2
91
6CEY6
114
P-6
(247)
2.0
45
1
87'
A1368G
Indy 440 XCR
360 380 380 He•
lndy600 XC
SN60-70LCDCSP
-01
593
Keihin PWK 39 (2)
AL
185 Hex
SN60-70LCDCSP
-02
600
Keihin PWK 39 (2)
AL
160 Hex
Indy Ultra/
Ultra Touring
EC68PL050
679
VM38 (3) AL
340 Hex
40
1
lndy700 XC
SN70-70LCDCSP
-02
701
Keihin PWK 39 (2)
AL
185
38
1
lndy700 XCR
EC68PL060
679
VM38 (3) AL
380
50
1
Indy 700 RMK
SN70-70LCDCSP
-01
701
Keihin PWK 39 (2)
AL
158
42
1
EC80PL052
794
VM38 (3) AL
PTOCtrMag
Indy 600 RMK
Indy Storm
f3
45
50
1/2
1
410 400 420
87"
6.5
FIXED
6.0
R1 368G
N2
FIXED
87'
6DH8
#2
P-4
(247)
87'
R1 388G
6.0
•3
FIXED
91
6CEY6
114
Q-2
(247)
87'
A1371G
•3
FIXED
91
6CGY6
N3
2.0
3.0
5.5
Q-0
(247)
3.0CH
• Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89 .
9/97
5.3c
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Exploded View - Keihin
([~
Gasket~
Spring
f/
,~~
Adjuster
Lock Nut
~
~
~
~
~
Spring Seat
/
~ . / Retainer
V'~
Jet Needle
"E" Clip
/Vent
~
1
~,
~/ ~~/
,/e
~-~,.,.
Idle Adjustment
Screw
e/
Main Jet
~ Fuet Inlet Needle
a
Float
0-Ring
Polaris Industries Inc.
5.3d
9/97
FUEL SYSTEM/CARBURETION
Exploded View - VM30SS
Ref. Oty.
Description
1.
1 Asm., Mixing Chamber Top
2.
3.
4.
5.
6.
7.
8.
9.
10.
11 .
12.
13.
14.
15.
16.
1
(Incl. Gasket)
Spring, Throttle
Plate, Throttle
E-Ring
Jet Needle
Throttle Valve
Needle Jet
Cap
Cap, Plunger
Spring, Plunger
Asm., Plunger
Spring, Throttle Adjuster
Screw, Throttle Stop
Screw, Air
Spring, Throttle Stop Screw
Pilot Jet
17.
4 Asm., Screw and Washer
9/97
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref. Qty.
18.
19.
20.
21.
22.
23.
24.
Description
25.
26.
1
1
1
1
1
1
1
1
2
Clamp, Hose
Clamp, Hose
Plug, Trap
Line, Fuel
Nipple
0-Ring
Main Jet
Washer
Asm ., Carburetor {Incl.
27.
28.
29.
30.
31.
32.
33.
2
2
1
1
1
1
1
Asm., Float
Cap
Gasket, Float Chamber
Needle & Seat
Packing, Needle Valve
Arm, Float
Pin, Float
1.-17.,23.-33.)
5.4
Polaris Industries Inc.
FUEL SYSTEM/CAABURETION
Exploded View - VM34SS
2
3
e-9
4
· - 10
r--11
)
r:
Ref. Oty
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Description
Ref. Oty
1
1
1
1
(Incl. Gasket)
Spring, Throttle
Plate, Throttle
E-Ring
Jet Needle
Throttle Valve
Needle Jet
Cap
Guide, Holder
Spring, Plunger
Asm., Plunger
Asm. , Carburetor
(Incl. 1.-17.,23.-31.)
Screw, Air
Spring, (Air Adjuster)
Spring, Throttle Adjuster
Screw, Throttle Stop
Polaris Industries Inc.
Description
17.
1 Pilot Jet
18.
1 Plate
19.
1 Ring
20.
1 Main Jet
21.
1 Gasket, Float Chamber
22.
2 Asm., Float
23.
4 Asm., Screw and Washer
24.
1 Clamp, Hose
25.
1 Clamp, Hose
26.
1 Plug, Trap
27. AR Tube, Sediment
28.
1 Nipple
29.
1 0 -Ring
30.
1 Arm, Float
31.
1 Pin, Float
32.
1 Asm., Fuel Inlet Needle Valve
33.
1 Packing, Needle Valve
1 Asm., Mixing Chamber Top
1
1
1
1
1
1
1
1
1
1
2
/
5.5
9/97
FUEL SYSTEM/CARBURETION
Exploded View - VM38SS
t-::34.
i-33.
t
32.
)
( _,/
15.
15.
Ref. Qty
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
9/97
Description
Ref. Qty
1 Asm. , Mixing Chamber, Top
(Incl. Gasket}
1 Spring
1 Plate
1 E-Ring
1 Jet Needle (6F9-3)
1 Throttle Valve (2.5)
1 Needle Jet (P-8) (247)
1 Cap
2 Packing
1 Asm., Needle Valve (1.5)
1 Float Pin
1 Float Arm
2 Cap
2 Asm., Float
2 Asm., Carburetor (Incl.
1.-1 6.,22.-34.)
1 0-Ring
1 Nipple
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31 .
32.
33.
34.
5.6
2
2
AR
2
4
1
1
1
1
1
1
1
1
1
1
1
1
Description
Plug, Trap
Clamp, Hose
Line, Fuel
Clamp, Hose
Asm., Screw and Washer
Gasket, Float Chamber
Main Jet (#340)
Ring
Plate
Pilot Jet (#40)
Throttle Stop Screw
Spring
Air Screw
Spring
Asm., Plunger
Plunger Spring
Plunger Cap
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Exploded View - 1996-Current VM34SS with ACCS
1996-Current ACCS Systems
Air Box
4 Way Manifold I Float
Bowl Vent Control
ACCS 4-way
Manifold mounted to
air box
--_ Valve
Vent line
attachment to
handlebars
'
3-way Manifold -,
attachment (1996'ACCS Only)
'
I
4-way
Manifold
attachment
ACCS Valve
I
Mag Garb
Vent line attachment
to handlebars
=
EXAMPLE: 27L 27cm Length, Large Diameter
27 = 27cm Length
S = Small Diameter
L Large Diameter
3 Way Manifold I
Pilot Air Control
(1996 ACCS Only)
'
=
NOTE: There is only one ACCS valve. The illustration above has been
divided to show the separation of systems.
Do not change calibration setting
or serious engine damage may result.
Polaris Industries Inc.
---r-,""'--L..A
5 .7
9/97
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy Lite
EC34-2PM02
Carburetor Type - VM30SS
Main Jet - 145
Pilot Jet - 35
Cut Away- 2.5 AL
Air Screw- 1.5 Turn
Needle Jet- 0-6 {169)
Jet Needle- 5DP7-2
All.
Met.
(Ft)
Below ·20' F
BeloW · 29' C
·20' to +IO'F
·29' to ·12' C
•IO' to ••O' F
·12' to .s•c
Above +40'f
Above s •c
0.900
(0.3000)
155
'145
135
130
91)().1800
(3000-6000)
140
1800-2700
(8000-9000)
130
2700.3700
(!lel00-12000)
120
• Shaded zone should drop Jet Needle one position (raise E-ellp)
• • Production Serting
Indy Lite GT
EC34-2PM02
Carburetor Type - VM30SS
Main Jet- 145
Pilot Jet- 35
Cut Away - 2.5 AL
Air Screw- 1.5 Turn
Needle Jet- 0-6 {169)
Jet Needle- 5DP7-2
AMBIENT TEMPERATURE
Alt.
Met.
(FI)
Below·20' F
BeloW·29'C
·20' Jo +IO' F
·29' 10 · t2' C
+10.. 1o •4Q• F
·12' 10 •5'C
AOOve.o-40' F
Aboves•c
0.900
(!>-3000)
155
'145
135
130
900-1800
(3000.6000)
140
135
125
1800-2700
(6000.9000)
130
120
1'15
,
fC6
1'¥
2700-3700
(!lel00-12000)
I · ./:::..J
~:
>'
120
11'0·
'~"'12odp
. J\(1if
uo
"' s
,~,
.t~h1,00
tw'
.
·Shaded zone should drop Jet Needle one position (raise E-ellp)
• • Production Setting
Indy Lite Deluxe
EC34-2PME02
Carburetor Type- VM30SS
Main Jet- 145
Pilot Jet - 35
Cut Away- 2.5 AL
Air Screw- 1.5 Turn
Needle Jet- 0-6 {169)
Jet Needle- 5DP7-2
AMBIENT TEMPERATURE
Below ·20' F
BelOw ·29' C
·20' to +10'F
·29' to ·12' C
+10' to +40' F
·12' to +5'C
Above +40' F
Above 6' C
()-900
(0.3000)
155
145
135
130
AIL
91)().1600
(3000.6000)
140
135
Mel.
(Ft)
1800-2700
(600()-9000)
125
120
c:::::=J ·Sheded zone should drop Jet Needle one position (raise E-dip)
Indy Sport
EC44-3PM01
Carburetor Type- VM34SS
Main Jet - 180
Pilot Jet - 35
Air Screw- 1.25 Turn
Cut Away - 2.5 CH
Jet Needle- 6DH7-3
Needle Jet- P-4 (166)
BeloW·20' F
BeloW ·29'C
AIt
Met
(Ft)
()-900
(o-3000)
190
900-1800
(300o-8000)
180
1800-2700
(8000.9000)
160
270()-3700
(!lel00-12000)
145
·Shaded zone should drop Jet Needle one position (raise E-ellp)
11/95
5.8
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy Sport Touring
EC44-3PM01
Carburetor Type - VM34SS
Main Jet - 180
Pilot Jet - 35
Air Screw - 1.25 Turn
Cut Away - 2.5
Needle Jet - P-4 {166}
Jet Needle- 6DH7-3
Beklw ·20' F
Below ·29' C
Alt.
Met.
(Ft)
G-900
(G-3000)
190
180
90G-1800
(3001).6000)
180
165
180().2700
(600().9000)
180
270~700
(900().12000)
145
- Shaded zone should drop Jet Needle one position (raise E·dlp)
Indy TranSport
EC44-3PM01
Carburetor Type - VM34SS
Pilot Jet - 35
Main Jet - 180
Air Screw- 1.25 Turn
Cut Away- 2.5
Needle Jet- P-4 (166)
Jet Needle- 6DH7-3
Be!Qw ·20"F
Below ·29' C
All.
Met.
(ft)
D-900
(0.3000)
190
90().1800
(300().6000)
175
180().2700
(6000.9000)
\60
270~700
(900().12000)
150
-Shaded zone should drop Jet Needle one position (raise E-cllp)
• - Production Setting
Indy Super Sport
EC44-3PM02
Carburetor Type - VM34SS
Main Jet- 180
Pilot Jet- 35
Cut Away - 2.0
Air Screw- 1.25 Turn
Jet Needle - 6FJ6-3
Needle Jet - P-8 {166)
Be!Qw ·20' F
Be1Qw·29'C
().900
Alt.
(~000)
190
900.1800
(3000.6000)
180
Mel.
(Ft)
Indy Trail
EC50PM04
Carburetor Type- VM34SS
Main Jet - 220
Pilot Jet - 35
Cut Away - 3.0
Air Screw- 1.5 Turn
Jet Needle- 6DH7-3
Needle Jet - P-8 (166}
Bolow -20' F
Below ·29"C
Alt.
Mel.
(Ft)
o-900
(0.3000)
230
90().1800
(3001).6000)
210
180().2700
(6000.9000)
195
27oo-3700
(900().12000)
180
-Shaded zone shOuld drop Jet Needle one position (raise E-cllp)
Indy Trail Touring
EC50PME04
Carburetor Type - VM34SS
Pilot Jet- 35
Main Jet- 220
Cut Away - 3.0
Air Screw- 1.5 Turn
Jet Needle- 6DH7-3
Needle Jet - P-8 (166)
Above +40' F
All0vo5' C
Below·20' F
Beklw·29' C
AIL
Met.
(Ft)
D-900
(().3000)
250
240
90().1800
(3000.6000)
230
220
160().2700
(6000-9000)
210
2700.3700
(900().12000)
190
- Shaded zone should drop Jet Needle one position (raise E-clip)
Polaris Industries Inc.
5.9
11/95
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
lndy440 LC
EC45PL02
Carburetor Type - VM34SS
Main Jet - 260
Pilot Jet - 40
Cut Away - 2.0
Air Screw- 1.5 Turn
Jet Needle- 6DH7-2
Needle Jet- P-2 (480)
AMBIENT TEMPERATURE
Below ·20' F
Below ·29' C
·20' to +10'F
·29'1o -12' C
+10' 10 +40'F
·12' to •5' C
Above +40' F
Aboves• c
(D-3000)
280
260
240
230
All
90().1800
(3001).fl000)
250
240
Met.
(F1)
1800-2700
(600().9000)
230
2700.3700
(900().12000)
210
().900
230
,,. ·<>.
•210
220
~ • Shaded zone shoUld drop Jet Needle one position (raise E-<:llp)
Indy Classic
EC50PLE11
Carburetor Type - VM38SS
Main Jet - 340
Pilot Jet - 40
Cut Away - 2.5
Air Screw - 1.0 Turn
Jet Needle- 6F9-3
Needle Jet- P-8 (247)
AMBIENT TEMPERATURE
Below·20"F
Below ·29'C
·20' to +10' F
·29' 10 ·12' C
+I 0"10 +40' F
· 12' to +5' C
AboVe ... 40' F
360
'340
320
300
Aboves•c
().900
(0.3000)
900-1800
All.
Met.
(FI)
(3000.6000)
320
300
280
26Q
1800-2700
(600().9000)
280
260
f'
~
220 }:
270().3700
{900().12000)
240
~
210
J;;
-
•
2011
~- .;:~
7:''
I:=:::J -Shaded zone should drop Je1 Needle one posiUon (raise E-<:lip)
• - PrOduction Setting
Indy Classic Touring
EC50PL14
Carburetor Type- VM34SS
Main Jet - 240
Pilot Jet - 40
Cut Away - 3.0 CH
Air Screw- 3/4 Turn
Needle Jet- P-4 (480)
Jet Needle - 6EJ26-2
AMBIENT TEMPERATURE
().900
{D-3000)
All
Met.
(Ft)
Below -20' F
Below·29' C
·20' 10 +1O' F
·29' 1o ·12' C
o10"10 +40' F
.. 12' to +&· c
250
'240
230
900-1800
(3000-0000)
230
220
210
1800-2700
{600().9000)
210
200
19()
270().3700
(900().12000)
195
18&
178
Above +40"F
Above 5'C
220
~~.
f>
"
ti!
f80
,,
l66
( -~"·tl -Shaded zone Should drop Jet Needle one position (raise E-<:iip)
• - PrOdUC11on Setting
Indy 500
EC50PL11
Carburetor Type - VM38SS
Main Jet - 340
Pilot Jet - 40
Cut Away - 2.5 CH
Air Screw - 1 Turn
Jet Needle- 6F9-3
Needle Jet- P-8 (247)
Below·20' F
Below·29' C
Alt.
Met.
(FI)
1).900
{1).3000)
360
900.1800
i3001).6()00)
320
1800.2700
(600().9000)
280
270().3700
(900().12000)
240
- Shaded zone Should drop Jet Needle one position (raise E-<:llp)
··PrOduction Selling
11 /95
5.10
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy 500 SKS
EC50PL11
Carburetor Type- VM38SS
Main Jet- 340
Pilot Jet - 40
Cut Away - 2.5 CH
Air Screw- 1 Turn
Jet Needle- 6F9-3
Needle Jet- P-8 (247}
Balow-20' F
Below-29 ' C
At>ove .. 40' F
Aboves•c
().900
AIL
Met.
(Ft)
(G-3000}
360
'340
9()().1800
(300().8000)
320
300
1801).2700
(6001).9000}
260
270().3700
(9001).12000}
240
- Shaded zone should drop Jet Needle one posijion (raise E-ellp)
• - Production Setting
Indy 500 RMK
EC50PL15
Carburetor Type - VM38SS
Main Jet - 240
Pilot Jet- 45
Cut Away - 2.0
Air Screw- 1 Turn
Needle Jet - P-4 (247)
Jet Needle- 6F9-2
().900
(().3000}
260
Alt.
Met.
(Ft)
220
210
i·w,c<~;,.q
200
I -Shaded zone should raise Jet Needle two posttlons (lower E-ellp to 114)
• • Production Satllng
Indy WldeTrak GT
EC50PM03
Carburetor Type - VM34SS
Main Jet - 200
Pilot Jet - 30
Cut Away- 3.0 CH
Air Screw - 1 Turn
Needle Jet- P-6 {1 66)
Jet Needle- 6DH7-3
Below -20' F
Below-29' C
Alt.
Mat.
(A)
At>ove +40' F
Aboves• c
1).900
(1).3000}
210
200
9()().1800
(3001).6000)
195
165
18()().2700
(600().9000)
160
270().3700
(9001).12000)
160
- Shaded zone should drop Jet Needle one position (raise E-ellp)
Indy WideTrak LX
EC50PL12
Carburetor Type - VM34SS
Main Jet - 190
Pilot Jet - 35
Air Screw - 3/4 turn
Cut Away - 3.0
Needle Jet- P-6 (166)
Jet Needle - 6EJ26-2
Below-20' F
Balow-29' C
Att.
Met.
(Ft}
().900
(1).3000)
200
9()().1 800
(3001).6000)
165
1801).2700
(8001).9000)
170
2701).3700
(9001).12000)
150
-Shaded zone should drop Jet Needle one posHion (raise E-ellp)
• - Production Setting
Polaris Industries Inc.
5.11
11 /95
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy 440 XCR
EC45PL07
Carburetor Type- VM34SS
Main Jet- 260
Pilot Jet- 50
Cut Away - 2.0
Air Screw - 1 Turn
Needle Jet- 0-4 (286)
Jet Needle - 6DH3-3
BeloW ·20' F
Below·29' C
Alt.
Met.
(F1)
Abolle +40' F
Aboves• c
Q-900
(Q-3000)
270
"260
90().1800
(3000-8000)
260
240
180Q-2700
(6000-9000)
230
2700-3700
(900().12000)
210
- Shaded zone should drop Jet Needle one position (raise E-<:lip)
• • Production Setting
Indy 440 XCR SP
EC45PL08
Carburetor Type- VM34
Main Jet- 260
Cut Away - 2.0
Jet Needle - 6DH3-3
Bel0w · 20' F
6eloW-29' C
Pilot Jet - 50
Air Screw- 1 Turn
Needle Jet - 0-4 (286)
Alt.
Met.
(Ft)
Q-900
(Q-3000)
280
90().1800
(3000-6000)
260
1800-2700
(6000-9000)
230
2700-3700
(900Q-12000)
200
·Shaded zone should drop Je1 Needle one posll/on (raise E-dlp)
Indy 600 XCR
EC58PL02
Carburetor Type- VM38AL Slide
Main Jet - 260
Pilot Jet - 35
Cut Away- 2.5
Air Screw - 1.0 Turn
Needle Jet- Q-2 (247)
Jet Needle - 6DH7-3
6elow-20' F
BeloW·29' C
Alt.
Met.
(Ft)
Above +40•F
Aboves• c
().900
(0-3000)
270
260
240
230
90().1800
(3000-6000)
250
240
220
210
1800-2700
(6000-9000)
220
220
2700-3700
(9000-12000)
200
200
- Shaded zone should drop Jei Needle one position (raise E-<:lip)
Indy 600 XCR SP
EC59PL01
Carburetor Type - VM38SS
Main Jet - 400
Pilot Jet - 40
Air Screw- 1.5 Turn
Cut Away - 2.5
Jet Needle- 6CEY6-3
Needle Jet - R-0 (247)
Below·20' f
6elow-29'C
Alt.
Mel
(Ft)
Abova+40'F
Above5' C
Q-900
(0-3000)
420
400
9oo-1800
(3000-6000)
390
370
1801).2700
(6001).9000)
350
2700-3700
(9000-12000)
310
- Shaded zone should drop Jet N eedle one position (raise E-<:tlp)
Indy XLT
EC58PL03
Carburetor Type - VM34SS
Main Jet- 210
Pilot Jet- 35
Air Screw- 1.0 Turn
Cut Away - 2.0
Needle Jet- Q-2
Jet Needle- 6DP1 7-3
Be!oW·20' F
Below·29'C
Alt.
Met.
(FI)
Q-900
(().3000)
220
90().1800
(3000-6000)
200
1800-2700
(600().9000)
175
2701).3700
(900().12000)
160
· Shaded zone should drop Je1 Needle one posHion (relse E-<:llp)
11 /95
5.12
Polaris Industries Inc.
-..___/
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy XLT SKS
EC58PL03
Carburetor Type- VM34SS
Main Jet- 210
Pilot Jet- 35
Cut Away- 2.0
Air Screw- 1.0 Turn
Needle Jet- Q-2 (166)
Jet Needle - 6DP17-3
Below-20' F
Below-29 ' C
Alt.
Met.
(Ft)
Above +40' F
Above 5' C
G-1100
(().3000)
220
210
200
900.1800
(3()()().6000)
200
190
180
180()-2700
(800()-9000)
175
170
270().3700
(900()-12000)
160
150
185
- Shaded zone should drop Jet Needle one position (raise E-ellp)
'----"
Indy XLT RMK
EC58PL07
Carburetor Type- VM34SS
Main Jet- 190
Pilot Jet- 35
Pilot Air Jet 1 (PAJ1)- 1.0
Pilot Air Jet 2 (PAJ2) - 1.6
Air Screw- N/A (ACCS)
Cut Away - 2.0
Needle Jet- Q-6 (480)
Jet Needle- 6DP17-3
AMBIENT TEMPERATURE
Main
Jet
Below-20' F
Bolow ·29' C
-20' to +10' F
-29' to ·12'C
t-10°10 +40°F
·12' to +5 ' C
Above +40 ' F
Above6' C
230
210
.,go
180
• - Production Setting
Indy XLT SP
EC58PL02
Carburetor Type- VM38AL
Main Jet- 260
Pilot Jet - 35
Cut Away - 2.5
Air Screw- 1.0 Turn
Needle Jet - Q-2 (247)
Jet Needle- 6DH7-3
Below-20 ' F
Bolow-29'C
()-900
Alt.
Met.
(A)
(()-3000)
270
91)()-1600
(300()-6000)
260
160()-2700
(800()-9000)
220
270()-3700
(900()- t 2000)
200
-Shaded zone should drop Jet Needle one posttlon (raise E-<:hp)
Indy XLT Touring
EC58PLE05
Carburetor Type- VM34SS
Main Jet- 250
Pilot Jet- 35
Cut Away - 2.5
Air Screw- 1.0 Turn
Jet Needle- 6DP17-3
Needle Jet- Q-2 (166)
Below -20' F
Below-29'C
All.
Met.
(Ft)
()-900
(().3000)
270
900.1600
(300()-6000)
240
160()-2700
(600()-9000)
220
27()().3700
(900()-12000)
200
-Shaded zone should drop Jel Needle one position (raise E-<:lipJ
• - Production Setting
Polaris Industries Inc.
5.13
11/95
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy Ultra RMK
EC6BPL04
Carburetor Type- VM38
Main Jet - 280
Cut Away - 1.5
Jet Needle- 6DHB-2
D-900
(D-3000)
Pilot Jet- 50
Air Screw- 1.0 Turn
Needle Jet- P-4 (247)
All.
Met
(Ft)
9()().1800
(300().6000)
180().2700
(600().9000)
290
' 280
270
260
270().3700
(900().12000)
270
260
250
240
·Shaded zone change cylinder head
c::::::::J ·Shaded zone produe11on setting
No Jet Needle Changes are Recommended
Indy Ultra SKS
EC68PL01
Carburetor Type - VM38
Main Jet- 340
Cut Away - 2.0
Jet Needle- 6DH8-2
AMBIENT TEMPERATURE
Pilot Jet - 50
Air Screw - 1.0 Turn
Needle Jet - P-4 (247)
All
Mel.
(Ft)
Indy Ultra SP
EC6BPL01
Carburetor Type- VM38
Main Jet - 340
Cut Away - 2.0
Jet Needle - 6DH8-2
Betow·20'F
Below·29' C
·20' 10 +10' F
-29' to ·12'C
+10 11tO +-40" F
·12' to +5' C
Above +40' F
Abovo6' C
D-900
(D-3000)
350
340
320
300
9()().1800
(300(). 6000)
320
310
300
280
180().2700
(600().9000)
290
280
270
260
270().3700
(900().12000)
270
260
250
240
AMBIENT TEMPERATURE
Pilot Jet- 50
Air Screw- 1.0 Turn
Needle Jet- P-4 (247)
AIL
Met.
(Ft)
Indy Storm
EC80PL05
Carburetor Type- VM38SS
Main Jet- 400-400-420
Pilot Jet- 45
Air Screw- 1.0 Turn
Cut Away - 3.0
Needle Jet- Q-0 (247)
Jet Needle - 6CGY6-3
Below ·20' F
Below -29' C
·20• to +10•F
+10• to +40• F
·29' 10 -12' C
·12° to .s·c
Above +40"F
AboveS ' C
D-900
(D-3000)
350
340
320
300
9()().1800
(300().6000)
320
310
300
280
180().2700
(600D-9000)
290
280
270
260
270().3700
(9000-12000)
270
260
250
240
BelOw -20' F
Below·29' C
All
Mel.
D-900
(Q-3000)
420
420
440
90().1800
(300D-6000)
390
390
410
(Ft)
180().2700
(600().9000)
360
360
380
270().3700
(900().12000)
320
320
340
- Shaded zone should drop Jet Needle one positton (raise E-<:lip)
c::J -Produe11on SeHing
?TO smaiiBSt- Mag biggest, PTO-center-Mag left to right
11/95
5.14
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts
Indy Storm SKS
EC80PL05
Carburetor Type- VM38SS
Main Jet - 400-400-420
Pilot Jet- 45
Air Screw- 1.0 Turn
Cut Away - 3.0
Jet- Q-0 (247)
Needle
Jet Needle - 6CGY6-3
Below·20'F
Below ·29'C
Alt.
Met.
0.900
(0.3000)
420
420
440
900.1800
(3000.6000)
390
390
410
(Ft)
1800.2700
(8000.9000)
2700.3700
(9CIOG-t2000)
"---"'
360
360
360
320
320
340
-Shaded zone should drop Jet Needle one poslllon (rallle E-<:lip)
c:::J ·
Production Selling
PTO smallest - Mag biggest, PTO-Center-Mag left to right
Indy Storm RMK
EC80PL04
Carburetor Type - VM38SS
Main Jet - 330-330-350
Pilot Jet - 50
Air Screw- 1.0 Turn
Cut Away - 3.0
Needle Jet - P-6 (247)
Jet Needle - 6CGY6-3
0.900
(1>-3000)
310
310
330
300
300
200
200
310
300
c:::J -
Production Setting
c:::=:J -Shaded zone shQ!Jid drop Jet Needle one posillon (raise E-<Jiip)
PTO smallest - Mag biggest, PTO-Center-Mag le1t to right
Polaris Industries Inc.
5.15
11/95
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy Lite
EC34-2PM02
Carburetor Type- VM30SS
Main Jet- 150
Pilot Jet- 35
Cut Away- 2.5 AL
Air Screw- 1.5 Turn
Jet Needle- 5DP7-2
Needle Jet- 0-6 (169)
Below-20•F
Below-29"C
Alt.
Met.
(F1)
0-900
{0-3000)
i60
900-1600
(3000-6000)
145
1800-2700
(6000-9000)
13{)
2700-8700
(!l000-12000)
115
-Shaded zone should drop Jel Needle one position (raise E-<:hp)
Indy Lite GT
EC34-2PM02
Carburetor Type- VM30SS
Main Jet - 150
Pilot Jet - 35
Air Screw - 1.5 Turn
Cut Away - 2.5 AL
Jet Needle- 5DP7-2
Needle Jet - 0-6 (169)
AMBIENT TEMPERATURE
All.
Met.
\Ft)
Indy Lite Delu xe
EC34-2PM02
Carburetor Type - VM30SS
Main Jet - 150
Pilot Jet- 35
Air Screw- 1.5 Turn
Cut Away- 2.5 AL
Jet Needle- 5DP7-2
Needle Jet - 0-6 (169)
Below-20" F
Below -29"C
-20" 10•10' F
-29" to -12"C
+10' 1G+40' F
·12' 10 +5" C
Above+~ O·F
0-900
(0-3000)
160
150
140
135
900-1800
(3000-6000)
145
140
1800-2700
(6000-9000)
130
2700-3700
(9000-12000)
115
Aboves• c
Below-20" F
Below-29' C
Alt.
Met.
(Ft)
0-900
(0-3000)
160
900- t SOO
(3000-6000)
145
1800-2700
(6000-9000)
130
2700-3700
(9000-12000)
115
- Shaded zone should drop Jet Needle one position (raise E-<:i1p)
Indy Sport
EC44-3PM02
Carburetor Type- VM34SS
Main Jet- 185
Pilot Jet - 35
Air Screw - 1 Turn
Cut Away- 2.0
Needle Jet- P-8 (166)
Jet Needle - 6FJ6-3
Below-20" F
Below ·29' C
AIL
Met.
(Ft)
0-900
(0-3000)
195
900-1800
(3000-6000)
185
1800-2700
(6000-9000)
2700-3700
(9000-12000)
Indy Sport Touring
EC44-3PM02
Carburetor Type - VM34SS
Main Jet- 185
Pilot Jet- 35
Cut Away - 2.0
Air Screw- 1.0 Turn
Jet Needle- 6FJ6-3
Needle Jet- P-8 (166)
9/96
Belo-.v-20"F
Below-29'C
Alt.
0-900
\0-3000)
195
900-1800
(3000-6000)
185
Met.
(Ft)
5.15a
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy TranSport
EC44-3PM02
Carburetor Type - VM34SS
Main Jet - 185
Pilot Jet - 35
Cut Away - 2.0
Air Screw- 1.0 Turn
Jet Needle - 6FJ6-3
Needle Jet- P-8 (166)
Alt.
Mel.
(Ft)
Indy Super Sport
EC50PM06
Carburetor Type- VM34SS
Pilot Jet- 45
Main Jet - 250
Cut Away - 2.0
Air Screw- 1 Turn
Needle Jet- 0-8 (480)
Jet Needle- 6DH7-3
0·900
(().3000)
195
9 0()-1 800
j300().6000)
185
180()-2700
(800()-9000)
AMBIENT TEMPERATURE
BefOYJ ~20"F
Below ·29 C
-20° to +1o~:~ F
·29"10 ·12"C
-+tO •to +1\0, F
· 12" to
Abovo +40• f
Above 5 C
0·900
(().3000)
260
250
240
230
Alt.
900-1800
(300().60001
250
230
Me!.
(Ft)
180().2700
(600()-9000)
220
270()-3700
(90CXJ.12000)
210
.s•c
~
~ - Shaded zone should drop Jet Needle one posillon [raose E-ci•Pl
Indy Trail
EC50PM04
Carburetor Type - VM34SS
Main Jet - 230
Pilot Jet- 35
Cut Away- 3.0
Air Screw - 1.5 Turn
Needle Jet- P-8 (166)
Jet Needle - 6DH7-3
AMBIENT TEMPERATURE
All.
Mel.
(F1)
Indy Trail Tou ring
EC50PM04
Carburetor Type- VM34SS
Main Jet - 230
Pilot Jet - 35
Cut Away - 3.0
Air Screw - 1.5 Turn
Jet Needle- 6DH7-3
Needle Jet- P-8 (166)
Below ..20<"F
Below -2e•c
·20' lO+l0° F
+10 !0 +40• F
·29 ·to · 12' C
-12• to •s· c
Above +40 " F
Above s•c
0·900
(().3000)
24 0
230
220
210
90()-1800
(300()-6000)
220
210
1800·2700
(6000·9000}
200
270().3700
(9000-12000)
190
AMBIENT TEMPERATURE
Below ·29' C
-2Qil> to +10°F
·29' to ·12' C
t10• to +40-) F
·12" lo +S" C
Above +-404 F
Above S"C
0·900
(().3000)
240
2 30
220
210
900-1800
(3 00().6000)
22 0
210
1600-2700
(6000-9000)
200
2700-3700
(900CH 2000)
190
Below -20~~"F
All.
Met.
(FI )
Indy Trail RMK
EC50PM05
Carburetor Type - VM34SS
Main Jet- 270
Pilot Jet - 45
Air Screw- 1 Turn
Cut Away - 2.0
Needle Jet- P-2 (480)
Jet Needle - 6DH7-2
AMBIENT TEMPERATURE
All.
Met.
(Ftl
BeiOw-20' F
Be10w·28· C
-20• to .,.10"'F
·29' 10 -12"C
-+ IO• to +-40 .. F
0·900
(0.3000)
3 10
290
270
#4
#3
#3
il2
900.1800
1300().6000)
310
290
113
270
112
250
180()-2700
l600D-9000)
310
113
290
2 70
250
~2
#2'
#2
270~700
310
29 0
270
2 50
(9000-12000)
#2
#2
112
Ill
#3
·t2• to
+S·c
Above J-40 F
Abovos· c
250
112
• - Productton Setti ng
Polaris Industries Inc.
5.15b
9/96
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy 440 LC
AMBIENT TEMPERATURE
EC45PL09
Carburetor Type - VM34SS
Main Jet - 270
Pilot Jet- 40
Cut Away - 2.0
Air Screw- .75 Turn
Needle Jet- P-2 (480)
Jet Needle- 6DH7-2
All.
Mel.
(Fl)
Below ·20' F
Below · 29' C
·20' lo ~ IO' F
·29' 10 · 12' C
+1 0' to +40' F
·12' 10 +5' C
Above +40"F
Above S' C
().900
(().3000)
290
270
250
240
90().1800
(3000.6000)
260
250
180().2700
(600().9000)
240
270().3700
(90()().12000)
220
Indy 500 Classic
AMBIENT TEMPERATURE
ECSOPL 17
Carburetor Type- VM38SS
Pilot Jet- 40
Main Jet - 350
Air Screw- 1.0 Turn
Cut Away- 2.5CH
Needle Jet- P-8 (247)
Jet Needle- 6F9-3
Alt.
Mel.
(Ft)
Below ·20' F
Below ·29 · c
·20' to +1O' F
·29' to -i 2' C
· 1O'lo +40' F
- 12' to +5' C
Abo•t e +40' F
Aboves•c
0·900
(().3000)
370
'350
330
310
90().t800
(300(}6000)
330
310
180(}2700
(600(}9000)
290
270
250
240
270().3700
(90()().12000)
L." l:tF :l - Shaded zone should drop Jet Needle one pos1 tlon (ra.se E-clip)
• • Production Selling
Indy Classic Touring
AMBIENT TEMPERATUR E
EC50PL 19
Carburetor Type - VM34SS
Main Jet- 250
Pilot Jet- 40
Cut Away - 3.0 CH
Air Screw- 1.0 Turn
Needle Jet- P-2 (480)
Jet Needle- 6EJ26-3
All
Met.
(Ft)
Below ·20' F
Below · 29' C
·20' 10 +10' F
·29'10 ·12' C
+IO' to t4 0' F
· 12' to +5' C
Above+40' F
Abovo 5' C
0·900
(().3000)
260
' 250
240
230
90().1800
(300(}6000)
240
230
160().2700
(600().9000)
220
270(}3700
(90()().12000)
200
li@@f F' I . Shaded zone should drop Jet Needle one position (raise E-<:l1p)
• - Praducllon Setting
Indy 500
EC50PL17
Carburetor Type- VM38SS
Main Jet- 350
Pilot Jet- 40
Cut Away - 2.5CH
Air Screw- 1.0 Turn
Jet Needle- 6F9-3
Needle Jet- P-8 (247)
Below ·20' F
BeloW ·29' C
All.
Met.
(Ft)
().900
(().3000)
370
90(). 1800
(300().6000)
330
160().2700
(600(}9000)
290
270().3700
(900(}12000)
250
• Shaded zane should drop Jet Needle one position (ra,se E-clip)
• - Praducllon Setting
9/96
5.15c
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy XCF
EC44-3PM02
Carburetor Type- VM34SS
Main Jet - 185
Pilot Jet - 35
Cut Away- 2.0
Air Screw- 1 Turn
Jet Needle - 6FJ6-3
Needle Jet - P-8 (166)
Below ·20' F
BaiOW·29' C
Alt.
Met.
(F1)
Indy 500 SKS
EC50PL17
Carburetor Type- VM38SS
Main Jet - 350
Pilot Jet - 40
Cut Away- 2.5CH
Air Screw- 1.0 Turn
Jet Needle- 6F9-3
Needle Jet- P-8 {247)
().900
1().3000)
195
90().1800
(300().6000)
185
1800.2700
(600().9000)
AMBIENT TEMPERATURE
Below ·20"F
Below -29 ' C
·20' to +1 O' F
·29' to ·t2' C
+1 0' 1o ••O' F
·12" 10 •S" C
Above +40' F
Atx>Ves• c
(().3ooo>
370
'350
330
310
90().1800
1300().6000)
330
310
180().2700
1600().9000)
290
270
270().3700
(\l()00-12000)
250
240
().900
All.
Met.
(Ft)
h~6Yi:Xd
• Shaded zone should drop Jet Needle one posmon (raise E-chp)
• · Producuon Setting
Indy 500 RMK
EC50PL16
Carburetor Type- VM34SS
Main Jet- 250
Pilot Jet - 40
Cut Away- 2.5CH
Air Screw- .75 Turn
Jet Needle- 6EJ26-3
Needle Jet- P-2 (480)
AM BIENT TEMPERATURE
Alt.
Met.
1ft)
Below·20' F
Below ·29' C
·20' to +IO'F
·29 lo ·12 C
+10"' to +40, F
().900
((1.3000)
290
270
250
#4
114
#4
240
#3
90().1800
(300().6000)
290
270
250
240
114
lt4
#3
#3
180().2700
1600().9000)
290
270
'250
240
#4
#3
~
#3
270().3700
(900(1.12000)
290
#3
270
250
#3
#3
Aoove +40' F
Aboves • c
·12 lo+S" C
-
tX(
LSi,.: " ·j - Shaded zona should ra1se Jet Needle one post1ton (lower E-<lltp to #3)
c::::::::J -Shaded zona should rats a Jet Needle two positions (lower E-clip to 114)
• - Production Setting
Indy WideTrak GT
EC50PM03
Carburetor Type- VM34SS
Main Jet- 200
Pilot Jet- 30
Cut Away - 3.0 CH
Air Screw - 1 Turn
Needle Jet- P-6 (1 66)
Jet Needle- 6DH7-3
Below ·20' F
8etow -29'C
All.
Met.
(Fl)
0·900
{().3000)
210
900.1800
(300().6000)
195
180().2700
(800().9000)
180
270().3700
(900().12000)
160
-Shaded zone should drop Jet Needle one position {raise E-cllp)
• - Production Selling
Polaris Industries Inc.
5.15d
9/96
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy WideTrak LX
EC50PL20
Carburetor Type- VM34SS
Main Jet - 195
Pilot Jet - 35
Cut Away - 3.0
Air Screw- 1/2 turn
Needle Jet- P-6 (166)
Jet Needle - 6EJ26-2
Below ·20 F
Betow -29 "C
Alt.
Met.
(A )
0-900
1()-3000)
205
90()-1800
(300()-6000)
190
160()-2700
(600()-9000)
175
2701>-3700
(900Q-12000)
155
- Shaded zone should drop J et Needle one posliion (raise E-cllp)
• - Production Seltlng
Indy 440 XC
EC45PL08
Carburetor Type- VM34SS
Main Jet - 240
Pilot Jet - 50
Cut Away - 1.5
Air Screw- .75 Turn
Jet Needle - 6DH3-3
Needle Jet- 0-4 (286)
AMBIENT TEMPERATURE
Bolcw- 20"F
Alt.
Met.
(FI)
1·.
Indy 600 XCR
EC59PL01
Carburetor Type- VM38SS
Main Jet - P-360/C-380/M-380 Pilot Jet - 40
Air Screw- .5 Turn
Cut Away - 2.0
Needle Jet- P-6 (247)
Jet Needle - 6CEY6-4
Below .zg•c
· 20" 10 •10"F
·29' 1o -12' C
•10" to • 40 F
·12' to +5' C
Abave +40' F
Above s•c
()- 900
(1>-3000)
250
240
230
220
90()-1800
(3001>-6000)
230
220
1801>-2700
(6001>-9000)
210
270()-3700
(9000- 12000)
195
/tJ -Shaded zone should drop Jet Needle one pos1110n (r!llse E-dtp)
Belaw ·20' F
Belaw·29 ' C
()-900
(0·3000)
Alt.
Met.
(FI)
400
90()- 1800
(3000·6000)
380
360
1800-2700
(600()-9000)
Indy 600 XCR SE
EC59PL01
Carburetor Type- VM38SS
Main Jet - P-360/C-380/ M-380 Pilot Jet- 40
Air Screw- .5 Turn
Cut Away - 2.0
Needle Jet- P-6 (247)
Jet Needle - 6CEY6-4
B elow -20' F
Below ·29•C
G-900
(0·3000)
All.
Met.
(FI)
400
90()-1800
(300()-6000)
380
360
180()-2700
(6000·9000)
9/96
5.1 5e
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy 600 XC
EC58PL08
Carburetor Type - VM38SS
Main Jet - 270
Pilot Jet - 35
Air Screw - .75 Turn
Cut Away - 2.0CH
Needle Jet- 0 -2 (247)
Jet Needle- 6DH7-3
AMBIENT TEMPERATURE
A It
Met.
(Ft)
Below -20'F
Below ·29' C
·20' to + t o·F
·29 to ·12' C
0·900
(().;!000}
290
900-1800
(3000·6000)
1800-2700
(GD00-9000)
2700-3700
(900(). 12000)
... 1o•ro T4011 F
·12 to +S'C
AboYe -40 F
Above S' C
vo
250
240
260
250
240
230
2•10
230
220
210
220
210
200
190
C==:J ·Shaded zone should drop Jet Needle one position (ra1se E-eltp)
\.._..
Indy XLT
EC58PL03
Carburetor Type - VM34SS
Main Jet · 220
Pilot Jet - 35
Cut Away · 2.0
Jet Needle- 6DP17-3
AMBIENT TEMPERATURE
Air Screw- 1.0 Turn
Needle Jet- 0-2 (166)
Alt.
Met
(Ft)
·•O
Betow-20 F
Below ·29'C
·20' to ~10 F
.zg· to ·12'C
.t o· to
F
- 12• 1o +s ~ c
Above +40" F
0·900
(Q-3000)
230
220
210
200
900-1800
(3000- 6000)
210
200
190
180
180().2700
(GD00-9000)
195
185
175
170
2700-3700
(900().12000)
180
170
170
170
AOoves· c
C==:J ·Shaded zone should drop Jet Needle one posn1on (raise E·chp)
Indy XLT SKS
EC58PL03
Carburetor Type - VM34SS
Main Jet - 220
Pilot Jet- 35
Cut Away - 2.0
Air Screw - 1.0 Tum
Jet Needle- 6DP17-3
Needle Jet - Q-2 (166)
AMBIENT TEMPERATURE
Below ·20'F
Below ·29'C
·20.. lo•l0"" F
+10' 1o+40'F
· 12 lo +S'C
Above +40' F
·29 10 ·12'C
230
220
210
200
(300Q.6000)
210
200
190
180
1800-2700
(6000·9000)
195
185
175
170
2700-3700
(9(00-12000)
180
170
170
170
0-900
(0.3000)
Aoovo s~ c
9()().1800
Alt.
Met.
(F1)
C==:J .
Indy XLT RMK
EC58PL07
Carburetor Type - VM34SS (ACCS)
Main Jet - 240
Pilot Jet - 50
Cut Away - 2.0
Air Screw- .75
Needle Jet- P-2 (480)
Jet Needle - 6EJ3-2
Shaded zone should drop Jet Needle one poslt1on (ra1se E·cllp)
AMBIENT TEMPERATURE
w Indicates E·cllp Locat1on from top o( Jet Needle
AIL
Met
(Ft)
Below ·20 F
Below ·29·C
·20 to. t O' F
·29 to ·12' C
+10'10 +"10 F
·12 10+5
Above t40' f
AbOve S'C
0·900
(0.3000)
280
260
N2
240
U2
230
HJ
9()().1800
(3000.6000)
280
260
#2
240
«2
230
1800-2700
(6000-9000)
280
260
M2
' 240
230
~2
~2
2700.3700
(9000-, 2000)
280
260
112
240
230
112
~1
n
~2
~2
c
"2
~2
• • Producti on Senlng
Polaris Industries Inc.
5.15f
9/97
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy XLT SP
EC58PL12
Carburetor Type - VM38ALSS
Main Jet- 270
Pilot Jet - 35
Cut Away- 2.0
Air Screw - 1.5 Turn
Needle Jet- Q-2 (247)
Jet Needle- 6DH7-3
Below·20' F
Below ·29' C
Alt.
Met.
(f1)
0·900
(()-3000)
290
90()-1600
(300()-6000)
270
160()-2700
(600()-9000)
240
270()..3700
(9000-12000)
220
-Shaded Z<lne should drop Je1Needle one position (raise E-chp)
Indy XLT Touring
EC58PL09
Carburetor Type - VM34CS
Main Jet- 260
Pilot Jet- 35
Cut Away- 2.5
Air Screw- 1.0 Turn
Needle Jet- Q-2 (166)
Jet Needle- 6DP17-3
Inlet Needle Seat - 1.5
Below · 20 F
Below·29· C
Ali.
Mel.
(Ft!
()-900
(()-3000)
280
90()-1800
(300()-6000)
250
180()-2700
(600()-9000)
230
270()-3700
(9000-12000)
21 0
-Shaded zone should drop Jet Needle one pas,lion (raise E-cllp)
• • Production Selling
Indy XLT LTD
EC58PL09
Carburetor Type - VM34CS
Main Jet- 260
Pilot Jet- 35
Air Screw - 1.0 Turn
Cut Away - 2.5
Needle Jet- Q-2 (166)
Jet Needle- 6DP17-3
Inlet Needle Seat - 1.5
Below·20' F
Below ·29•C
AIL
Mat.
(ft)
()-900
(()-3000)
260
90()-1600
(300()..6000)
250
160()-2700
(600()-9000)
230
270()-3700
(9000-12000)
!?10
- Shaded zone should drop Jet Needle one poSition (raise E-clip)
• - Production SeHing
Indy XLT LTD SP
EC58PL 12
Carburetor Type - VM38ALSS
Main Jet- 310
Pilot Jet - 35
Air
Screw- 1 Turn
Cut Away - 2.0
Needle Jet - Q-2 (247)
Jet Needle- 6DH7-3
BeloW -2o• F
Below -2e•c
All.
Met.
(FI)
G-900
(()-3000)
330
900.1600
(3000.6000)
310
\80()-2700
(6000.9000)
280
270()-3700
(9000-12000)
260
- Shaded zone shoold drop Jet Needle one position (raise E-cllp)
9/97
5.15g
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy Ultra
EC68PL01
Carburetor Type - VM38
Main Jet - 340
Cut Away - 2.0
Jet Needle- 6DH8-2
Indy Ultra SP
EC68PL01
Carburetor Type- VM38
Main Jet- 340
Cut Away- 2.0
Jet Needle - 6DH8-2
Indy Ultra Touring
EC68PL01
Carburetor Type - VM38
Main Jet - 340
Cut Away - 2.0
Jet Needle - 6DH8-2
Indy Ultra SPX
EC68PL03
Carburetor Type - VM38
Main Jet- 380
Cut Away- 3.0
Jet Needle - 6CEY6-4
AMBIENT TEMPERATURE
Pilot Jet - 40
Air Screw- 1.0 Turn
Needle Jet- P-4 (247)
Ali.
Met.
(Ft)
Above -+-40 •F
Balow ·20' F
8eiOW·29 "C
·20' to + 1O" F
·29"10 ·12' C
+10• to +4!rF
0·900
(G-3000)
350
340
32.0
300
90()-1800
(3QQO-OOOO)
320
310
300
280
1800.2700
(6000.9000)
2.90
280
270
260
270().3700
(9QQO-12000)
270
260
250
240
...12'
to ...s•c
Aboves• c
AMBI ENT TEMPE RAT URE
Pilot Jet - 40
Air Screw- 1.0 Turn
Needle Jet- P-4 (247)
Alt.
Met.
(Ft)
8eiQW·20' F
Below ·29'C
·20" 10 •10°F
+l0 1110 -;40"F
·29' to ·12' C
·12' 1o +5' C
Above+40' F
Aboves• c
D-900
(D-3000)
350
340
320
300
900.1800
(3000.6000)
320
310
300
280
1800.2700
(6000.9000)
2.90
280
270
260
2700.3700
(90CJ0. 12000)
270
260
250
240
AMBIENT TEMPERATURE
Pilot Jet - 40
Air Screw - 1.0 Turn
Needle Jet - P-4 (247)
Alt.
Met.
(Ft)
Be!Ow·20'F
Below ·29' C
-20• IO-t10"F
-29' to - 12' C
+10'to +4 0' F
-12' 10 +5"C
Above +40 ' F
Aboves •c
D-900
IG-3000)
350
340
320
300
9QO-t800
(3000.6000)
320
310
300
280
1600.2700
(6000.9000)
290
280
270
260
2700.3700
(9000-12000)
270
260
250
240
AMBIENT TEMP ERAT URE
Pilot Jet- 50
Air Screw- 1.0
Needle Jet - Q-2 (247)
Alt
Met.
(Ft)
BeiOW·20' F
Below ·29' C
·20' to +10' F
-29• 1o ·12"C
+10• to +40• F
·12" 10 .s• c
Above •40" F
At:>oves• c
0·900
(G-3000)
400
#4
'380
#4
360
340
#3
#3
90()-1800
(3000.6000)
370
350
330
#4
#3
#3
310
#2
160()-2700
(6000.9000)
340
320
300
280
#3
#3
lt2
112
2700.3700
(900(). t 2000)
310
290
270
#3
#2
112
250
111
• - Producllon Sett1ng
Indy Ultra SPX SE
EC68PL03
Carburetor Type- VM38
Main Jet- 380
Cut Away - 3.0
Jet Needle- 6CEY6-4
AMB IENT TEMPERATURE
8BIOW ·20' F
Below·29' C
Pilot Jet - 50
Air Screw - 1.0
Needle Jet- Q-2 (247)
Alt.
Met.
(Ft)
~2o•
to ...., o•F
+10"10 +40' F
·12" to ~s· c
Above +40° F
·29" to · 12' C
340
Above s• c
0·900
(().3000)
400
'380
360
114
#4
#3
#3
91)().1800
(3000.6000)
370
350
330
3 10
#4
113
#3
#2
1800.2700
(8000.9000)
340
320
300
260
#3
#3
lt2
#2
2700.3700
(9000-12000)
310
290
#3
112
270
#2
250
#1
• - Productton Selling
Polaris Industries Inc.
5.15h
9/96
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy 700 SKS
SN70LCDCSP-01
Carburetor Type - Keihin PWK 39
Main Jet- 185 Long Hex Pilot Jet- 40
Cut Away - 6.5
Air Screw - 1 Turn
Jet Needle- R1370G-3
Needle Jet- Fixed
AMBIENT TEMPERATURE
All
Met.
BeiOW·20"F
Below ·29'C
-20' to +10• F
·29" to -12"C
..-1o•to +40' F
-12"1o t5" C
Above ..-o· F
Aboves•c
0.900
(o-3000)
190
'185
178
172
91XH800
(3000.6000)
178
175
168
162
158
155
tSO
145
1800.2700
(6000.9000)
(FI)
270().3700
(900().12000)
HW~iti\il
IE
..
~,...
..
165 .. <·
·,
1~ i>
'
-Above 6000ft use JN R1370J.3. 5.0 CA. 55 pilot, and 1/2tum air screw
L:::=J · Lower
Jet Neeole 1 position (raise E-<:llp) and Install RMK components
listed above
• - Production Setting
Indy 700 RMK
SN?OLCDCS P-02
Carburetor Type - Keihin PWK 39
Main Jet - 158 Long Hex Pilot Jet - 55
Cut Away- 5.0
Air Screw -1/2 Turn
Needle Jet -Fixed
Jet Needle- R1370J-3
AMBIENT TEMPERATURE
·20" to-10'F
·29'to -12'C
+IO• to +40-c F
-12• to .. s•c
Above+40' F
Aboves•c
l;t 190
1~
178
112
Below·20"F
Below·29' C
t>-900
(O.:;oOO)
All.
Mat.
(Ft)
90(>.1800
(3000.8000)
.,
,.
17&
175
168
16~
1801).2700
(8000.9000)
168
165
' 158
155·
270<>-3700
(900().12000)
158
155
150
145'
J,,
c::::::::::::J · Lower Jet Needle 1 position (raise E-<:llp)
j<;)nfrmJ -Below 6000ft use JN R t 370G·3, 6.5 CA, 40 pilot. and 1 turn a1r screw
• • Production Setting
Indy 700 XC
SN?OLCDCSP-01
Carburetor Type - Keihin PWK 39
Main Jet - 185 Long Hex Pilot Jet - 40
Cut Away - 6.5
Air Screw- 1 Turn
Jet Needle- R1370G-4 Needle Jet -Fixed
AMBIENT TEMPERATURE
# Indicates E-<:IIP Location from top of Jet Needle
All.
Mel.
(Ft)
t--40' F
·12' to •S' C
AboiJO •40~F
178
172
#4
'185
#4
114
11-3
900.1800
(300().6000)
178
175
168
oj4
114
lt3
162
Jr3
1800.2700
(6000.9000)
168
.114
165
155
J:3
158
#3
2700.3700
{900().12000)
158
155
150
#3
113
><3
145
;t3
Below-20"F
Belcw·29'C
·20' to •IO"F
·29 10 ·12'C
().900
190
(0.3000)
..-10~ 1o
Aboves·c
;:3
• - Production Selling
Indy Storm
EC80PL05
Carburetor Type- VM38SS
Main Jet - 41 0-400-420
Pilot Jet - 50
Air Screw- 1.0 Turn
Cut Away - 3.0
Needle Jet- Q-0 (247)
Jet Needle - 6CGY6-3
AMBIENT TEMPERATURE
# lndJcales E-<:l1p location from lop of Jet Needle
#3
All.
Met.
(Ft)
Below ·20' F
Below -29"C
-20• to tiO' F
-29" 10 -12 ' C
..-TO• to .,40'F
·12 to •5' C
Above +-40• f
().900
(0.3000)
43014201440
•41 (){4001420
390/380/400
37013601380
#3
#3
#3
#3
90<>-1800
(3000.6000)
360/370/390
.113
360/3501370
340/330/350
32013101330
#3
#3
112
1800.2700
(6000.9000)
340/3301350
320010030
300/290/3 I 0
29012801300
113
#3
112
il2
270<>-3700
{900().12000)
29012801300
27M601280
24012301250
#3
112
25012401260
112
Aboves•c
il2
• - Production Settmg
Mag b199est. PTO.Center-Mag Jeh 10 nght
9/97
5.15i
Polaris Industries Inc.
~'
FUEL SYSTEM/CARBURETION
1997 Jetting Compensation Charts
Indy Storm SE
EC80PL05
Carburetor Type - VM38SS
Main Jet- 41 0-400-420
Pilot Jet- 50
Air
Screw - 1.0 Turn
Cut Away - 3.0
Needle Jet - Q-0 (247)
Jet Needle - 6CGY6-3
AMBIENT TEMPERATURE
113
All.
Mel.
(Ft)
Indy Storm RMK
EC80PL04
Carburetor Type - VM38SS
Pilot Jet- 55
Main Jet- 300-290-310
Air
Screw- 1.0 Turn
Cut Away - 2.5
Jet Needle - 6CGY6-3
Needle Jet - P-6 (247)
Below-20 ' F
Be10w·29'C
·20" 10 +10' F
·29 IO ·12' C
tl0°to +4 0•F
·12" to •5' C
Above +40'F
Above5 'C
37013601380
0.900
4301420/440
([).3000)
"41QI40Q/420
3901380/400
113
#3
113
113
900.!800
3801370/390
340/330/350
(300[).6000)
113
360050070
#3
113
320/31 01330
lf2
180[).2700
(600Q.9000)
3401330/350
3201310030
300129013 1 0
290/2801300
#3
112
112
270[).3700
(9(l0(}12000)
290/280/300
43
270/26012a0
2501240/260
#2
240/2301250
qa
#2
#2
AMBIENT TEMPERATURE
!t3
All.
Mel.
(Ft)
Below ·20' F
Bel0w -29 ' C
·20" to +10' F
·29' to ·12'C
..1o•to .. 4o· F
G-900
([).3000)
430/420/440
#4
41 0/400/420
#4
390/380/ 400
#4
37013601380
900.1800
36013501370
(3000.6000)
3801370090
#4
340/330/350
114
320/3101330
113
1800.2700
(600[).9000)
340/330/350
320/3101330
#4
"3001290131
0'13
29012801300
#4
270()..3700
(!IOOG-12000)
290/2801300
#4
2701260/280
'13
250/2401260
240/2301250
qa
tt2
#4
-t2o. to +S'C
AOO.e +40'F
Aooves• c
#4
113
• • Produc1lon Selling
Mag biggest. PTO-Center-Mag lett to nght
Indy 440 XCR
SN44LCDCSP-01
Carburetor Type - VM34SS
Pilot Jet- 40
Main Jet - 360
Air Screw- 1/2 Turn
Cut Away - 2.0
Needle Jet - P-4 (286 or 159)
Jet Needle - 6DH7-4
AMBIENT TEMPERATURE
II
All.
Mel.
(f1)
Indicates E-d1p Location from top ot Jet Needle
Below·20'F
Below ·29'C
-20' IO +1041 F
·29' 10 ·12' c
+10°10 +40'F
-12 "to .s·c
AboVe +40'F
Aoovos•c
0.900
([).3000)
380
#4
' 360
340
#4
113
320
#3
90(}1800
(300()-8000)
340
320
#3
300
280
113
!r3
180[).2700
(6000·9000)
300
#3
290
270
#3
#3
250
113
2700.3700
(900(} 12000)
270
260
113
240
#3
#4
#3
220
#3
• • PrOduction Sethng
Polaris Industries Inc.
5. 15j
9/97
FUEL SYSTEM/CARBURETION
1998 Jetting Compensation Charts
Lite
Lite Deluxe
Lite Touring
EC34-2PM02
VM30SS
Main Jet - 150
Pilot Jet - 35
Cut Away - 2.5 AL
Air Screw - 1.5 Turn
Jet Needle- 5DP7-2
Needle Jet- 0-6 (169)
AMBIENT TEMPERATURE
II Indicates E-clip Location from top of Jet Needle
Alt.
Met(Ft)
(cXloOO)
Beiow
-20' F
·29' C
-20 ' to
+10'F
-29' 10
-12• c
+10' \o
+40' F
-12' to •5' C
Above
t40' F
Above 5'C
160
"150
140
135
#2
#'2
#'2
145
140
130
#'2
#2
1'2
125
#1
130
125
#2
#2
120
#1
115
#1
115
115
#1
110
#1
105
It!
#'2
900.1800
(3000.6000)
180().2700
(6000.9000)
2700.3700
(900().12000)
#2
Sport
Sport Touring
TranSport
XCF
EC44-3PM024
VM34SS
AMBIENT TEMPERATURE
# Indicates E-clip Location from top ol Jet Needle
Alt.
Mei.{FI)
0.900
(0.3000)
Below
·20" F
Below
·29'C
-20' IO
+1 0'F
·29'to
-12'C
+10' 10
+40'F
- 12' to +5' C
Above
+40' F
Above5'C
195
" 185
175
165
#3
II:J
#2
185
170
160
150
#3
II:J
#'2
#2
165
155
145
135
#3
#2
#2
#2
150
145
135
125
#'2
#2
#2
#2
#3
Main Jet- 185
Pilot Jet - 35
Cut Away - 2.0
Air Screw- 1 Turn
Jet Needle- 6FJ6-3
Needle Jet - P-8 (1 66)
900.1800
(300Q.6000)
t600-2700
(600().9000)
270().3700
(900().12000)
AMBIENT TEMPERATURE
lndlcates E-clip Localion !rom top of Jet Needle
Super~ort
EC50P 061
VM34SS
Main Jet - 250
Pilot Jet- 45
Cut Away - 2.0
Air Screw- 1 Turn
Jet Needle- 6DH7-3
Needle Jet- 0-8 (480)
#
AIL
Met.(Ft)
().900
(().3000)
90().1800
(300().5000)
270().3700
(900().12000)
Alt.
MeL(Ft)
0·900
(Q-3000)
Above
+40' F
Above s• c
260
"250
240
230
#3
#3
#3
250
230
220
210
#3
#3
#3
112
220
210
#3
2 10
200
113
#2
112
210
200
200
200
#3
#2
#2
#2
90Q-1800
(3000.6000)
1600.2700
(600().9000)
Above
Below
·20' F
Below
·29" C
·20' to
+10'F
·29' to
·12" C
+40'F
-12• to ..s • c
240
"230
220
#3
#3
210
#3
220
210
200
190
#3
#3
#3
#2
200
195
185
180
#3
#3
#2
#2
190
180
180
180
113
#2
#2
#2
#3
2700.3700
(900().12000)
9/97
+1 0' \o
+40' F
·12' to +5' C
AMBIENT TEMPERATURE
# Indicates E-cllp Locat,on from top of Jet Needle
Trail
Trail Touring
Main Jet - 230
Pilot Jet - 40
Cut Away - 3.0
Air Screw- 1.0 Turn
Jet Needle- 6DH7-3
Needle Jet - P-8 (166)
·20' to
+10• F
·29' to
·12' C
#3
160().2700
(600().9000)
ECSOPM043
VM34SS
Below
-20'F
Below
·29'C
+10° tO
5.15k
~40' F
Above s•c
Polaris Industries Inc.
FUEL SYSTEMICARBURETION
1998 Jetting Compensation Charts
AMBIENT TEMPERATURE
II lnd1cales E·cl1p Localion from lop of Je1 Needle
Trail RMK
EC50PM051
VM34 (ACCS )
Main Jet • 270
Pilot Jet - 45
C ut Away - 2.0
Air Screw - 1 Turn
Jet Needle - 6EJ3-3
Needle Jet - 0-6 (480)
Alt.
Met.(FI)
0-900
{0-3000)
Below
·20'F
Below
·29'C
310
#3
·20' 10
+10' F
·29'1o ·12' C
+10°10
+40' F
·12' to +5 C
Above
+40' F
Above 5 C
290
-3
270
250
#3
~3
270
900·1800
(3000.6000)
310
H3
290
#3
•a
250
lf3
1800-2700
{6000.9000)
310
290
'270
N3'
250
#3
27()()..3700
310
290
#3
270
250
K3
(~ 12000)
~3
1t3
~3
#3
AMBIENT TEMPERATURE
# Indicates E·cllp Location from top of Jel Needle
440 LC
EC45 PL091
VM34SS
AlL
Below
·20' F
Below
·29'C
·20' 10
+10' F
·29 10
·12' C
+10' 10
+40' F
·12' I0+5' C
+40' F
Above s · c
0-900
(ll-3000)
290
•2
'270
#2
250
112
240
,2
(3000-&000)
900·1800
260
#2
250
#2
240
#2
230
,3
1800-2700
240
230
H2
42
220
N3
210
•3
220
#2
210
#3
200
#3
190
Met.(Ft)
Main Jet - 270
Pilot Jet - 40
Cut Away- 2 . 0
Air Screw- .75 Turn
Jet N eedle- 6DH7 -2
Needle Jet - P-2 (480)
(600Q.9000)
27()()..3700
(9000-12000)
1998 440 XCR
SN44-44LCDCSP-01
VM34SS
MainJet-360 Hex
P1lot Jet - 45
Cut Away - 2 .0
Air S c rew - 1 .5 Turns
Jet Needle - 6DH7-3
Needle Jet- P-4 (286)
Alt.
Below
·20'F
Below
·29'C
·20' to
+10' F
·29' 10
· 12' C
+tO•to
+40' F
·12 to+S'C
Above
+40' F
Above S' C
0·900
{ll-3000)
380
u
360
H3
340
#3
320
,3
OOll-1800
(3000-6000)
340
113
320
#3
300
#3
280
1800-2700
300
290
250
#3
#3
270
•3
27()()-3700
270
250
240
220
#3
#3
il3
#3
Met.(Ft)
(~120C<))
Main Jet - 350
Pilot Jet - 45
Cut Away - 2.5
Air Screw- .75 Turn
Je t Needle - 6F9-3
Needle Jet- P-6 (480 )
500 RMK
EC50PL 161
VM34SS ( ACCS)
Main Jet - 260
Pilot Jet - 55
Cut Away - 2.5
Air S c rew - 1 .25 Turn
Jet Needle - 6FJ43-2
Needle Jet- P-0 (480)
#3
#3
AMBIENT TEMPERATURE
ll lnd,ca1es E·chp Locahon from top of Jet Needle
Alt.
Met.(Ft)
Below
·20'F
Below
·29' C
·20' to
+10' F
·29'10
· 12' C
0-900
(0-3000)
370
350
900-1800
(3000.6000)
180().2700
+tO•to
+40F
· 12' 1o
+s·c
Above
+40' F
Above 5' C
330
#3
310
#3
330
•3
310
290
270
~3
~2
(6()00.9000)
290
#3
270
250
#2
230
#2
2700-3700
(9000-12000)
250
240
ir3
#2
220
112
210
•2
#3
~3
~3
~3
AMBIENT TEMPERATURE
# lnd1ca1es E·cllp Loeauon from lOP of Jet Needle
AIL
Met.(F1)
Below
·20' F
Below
·29 c
·20• to
+10 F
·29•to -12' C
+10' to
+40"F
·12 to+5C
Above
+40"F
Above s · C
0-900
290
270
~4
113
260
#3
2•10
#3
OOll-1800
(3()00.6000)
290
270
260
~4
83
#3
240
#2
1800-2700
(6000.9000)
290
113
270
"260
2i()()-3700
290
#3
270
#2
(0.3000)
(9000- t 2000)
Polaris Industries Inc.
~3
AMBIENT TEMPERATURE
# lnd1ca1es E·clip Locat1on from lop ot Jet Needle
(6()00.9000)
500
500 Classic
EC50PL171
VM38SS
Above
r13
#2
240
#2
260
112
240
112
5.151
9/97
FUEL SYSTEM/CARBURETION
1998 Jetting Compensation Charts
Classic Touring
EC50PL 191
VM34SS
Main Jet · 250
Pilot Jet - 40
Cut Away- 3.0 CH
Air Screw - 3/4 Turn
Jet Needle - 6EJ26-3
Needle Jet - P-2 (480)
WideTrak LX
EC50PL201
VM34SS
Main Jet - 195
Ptlot Jet - 35
C ut Away - 3.0
Air Screw - 112 turn
Jet Needle - 6EJ26-2
Needle Jet- P-6 {166)
XLT LTD
XLT Touring
EC58PL130
VM34SS
Main Jet - 240
Pilot Jet - 40
Cut Away - 2.5
Air Screw - 1.0 Turn
Jet Needle- 6DP17-3
Needle Jet- Q-4 {480)
XLTSP
EC58PL140
Type - VM38SS
Main Jet - 330
Pilot Jet - 35
Cut Away- 2.0
Air Screw - 1.5 Turn
Jet Needle- 6DH7-3
Needle Jet- Q-0 (247)
XLT Classic
EC58PL 150
VM38SS
Main Jet - 340
Pilot Jet - 35
Cut Away- 2.0
Air Screw- 1.5 Turn
Jet Needle- 6DH7-3
Needle Jet - Q-0 {247)
9/97
AMBIENT TEMPERATURE
# lndrcates E-clrp Location from top of Jet Needle
All.
Met.(Ft)
Below
·20 F
Below
· 29' C
·20' 10
+tO"F
-29' 10
· 12' C
+10" 10
+40' F
-12' to~ C
Above
+40' F
Above s·c
0·900
(0.3000)
260
u
' 250
240
230
~3
N3
~3
900-1800
(3000·6000)
240
220
W3
230
#3
210
#2
1800-2700
(600().9000)
220
210
185
~3
#3
195
#2
270().3700
(9()0(}12(.(())
200
•3
190
180
#2
~2
175
#2
#3
n
AMBIENT TEMPERATURE
~ l~drcates E-cllp Locatron from lOP ol Jel Needle
Alt.
Mel(Ft)
B elow
·20 F
B elow
-29' C
·20" 10
+ I O' F
·29 10
· 12' C
+10' 10
+40 ' F
·12' lo+5' C
Above
+40 ' F
Above 5" C
0·900
210
"2
'195
•2
185
1!2
175
,2
900-1800
190
•2
ISO
il2
170
•2
170
(3000-6000)
1900-2700
(600().9000)
175
#2
165
1!2
155
145
Nl
27()().3700
(900()-12000)
155
#2
150
N1
140
(D-3000)
Ht
~I
135
#1
~1
AMBIENT TEMPERATURE
# lndrcates E-cl!p Lcca11on trom top ol Jet Needle
Alt.
Met.( FI)
B elow
·20' F
B elow
·29• C
·20' 10
+10' F
·29"10
·12' C
+10" 10
+40' F
·12' I0+5' C
'240
220
~3
~3
Above
+40' F
Above
s•c
0·900
250
(0-3000)
#3
900-1600
230
113
220
#3
210
(3000-6000)
~2
195
M2
180CI-2700
(600().9000)
210
#3
200
#2
190
180
27()().3700
(9(XX} 12000)
190
113
180
112
175
#2
165
ll2
210
#3
n
~2
AMBIENT TEMPERATURE
11 lndrcates E·chp Lccatoon trom top of Jet Needle
All.
Mei.(A )
Below
·20' F
Below
-29' C
-20' 10
+10' F
·29"to
·12"C
+40• F
-12• to -t-S• C
Above
+40' F
Above 5' C
0·900
(0-3000)
350
113
'330
#3
310
lr3
300
lt3
900-1800
(3000·6000\
320
113
300
280
U3
270
180CI-2700
(6000.9000)
290
#3
270
240
#3
250
#2
27()().3700
(9()0(}12000)
270
#3
250
230
220
112
N2
#2
#3
+10' 10
42
#2
AMBIENT TEMPERATURE
N Indicates E·cllp location trom lop ot Jel Needle
Alt.
B elow
·20' F
Below
-29 c
· 20 10
+IO· F
·29 10
·12
+10' 10
+40 F
12 to+5C
Above
+40• F
Above5 C
0·900
(().3000)
360
'340
320
#3
310
~3
900-1800
(300().6000)
330
N3
310
290
280
~3
#3
~2
1900-2700
(600().9000)
300
H3
280
q3
260
#2
250
2700.3700
(9000- 12000)
280
260
240
230
#2
~2
Met.(Ft)
N3
#3
c
n
5.15m
#3
112
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
1998 Jetting Compensation Charts
AMBIENT TEMPERATURE
(PTO/CENTERIMAG)
# lnd<cates E~hp Location from top of Jet Needle
600 XCR
EC59PL020
VM38SS
All.
Met.(Ft)
MainJet- Pto/Cen/Mag
360/380/380
Pilot Jet - 40
Cut Away - 2.0
Air Screw - .5 Tum
Jet Needle - 6CEY6-4
Needle Jet- P-6 (247)
600 XC
SN60-701 CDCSP-01
Keihin - PWK 39
Main Jet-185 Long Hex
Pilot Jet - 45
Cut Away - 6.5
Air Screw - 1 Turn
Jet Needle- R1368G-3
Needle Jet - 2.9mm
Fixed
Main Jet - 160
Pilot Jet - 45
Cut Away - 6.0
Air Screw - .5
Jet Needle R1368G-2
Needle Jet- 2.9mm
F1xed
.. ,o~to
·20' 10
tlO•F
·29"to·12" C
·t2• to +5"C
t40.. F
AbOve ..SO" F
AbOVe s·c
0.900
(0.3000)
31!01400/400
••
'360/3SOI380
34 013601360
••
320/340/340
113
900.1800
(3001).6000)
340136(11360
3301350/350
31 0133(11330
~
29013101310
M3
1800.2700
(6000.9000)
31013301330
300132(11320
M3
28013001300
26012801280
2700.3700
(9CXJC).12000)
28013001300
113
27012901290
25012701270
240/260/260
~
#3
#4
••
#4
••
M3
.s
-3
AMBIENT TEMPERATURE
# Indicates E-<:llp Location from top of Jet Needle
Alt.
Met.(Ft)
Below
·20"F
Below
·29" C
·20'10
•10" F
·29"10
·12'C
+40'F
-12' to +5" C
0.900
(D-3000)
188
'185
178
113
113
172
#3
900.1800
(3000.6000)
178
175
168
162
113
113
113
1!3
1S00.2700
(60QC).9000)
168
165
113
160
155
#2
2700.3700
{90()().12000)
158
113
155
150
#2
112
600 RMK
SN60-70LCDCSP-02
Type-Keihin PWK 39
Below·20"F
Below-29"C
113
113
T10° 10
Above
+40" F
Above s•c
lt2
145
#2
AMBIENT TEMPERATURE
F Indicates E~tip Locahon from top of Jet Needle
Alt.
Met.(Ft)
Below
·20'F
Below
·29' C
-20' to
+10' F
-29'to ·1 2'C
~'
+10"10
+40'F
·12' to +5'C
AboVe
+40'F
Above s•c
:' :"'i @;0 v~~/:/
0·900
(D-3000)
/~
900.1800
13000.6000)
178
175
#2
168
#2
162
lt2
160D-2700
(6000.9000)
168
165
1/2
112
' 160
112
155
#1
2701).3700
(9CXJC).12000)
158
#2
155
#2
150
#1
145
#11
I"
/
/
112
G:=2J ·Shaded zone tum Air Screw to 1 turn
Ultra
Ultra Touring
EC68PL050
VM38
Main Jet - 340
Pilot Jet- 40
Cut Away - 2.0
Air Screw- 1.0 Turn
Jet Needle - 6DH8-2
Needle Jet - P-4 (247)
AMBIENT TEMPERATURE
# Indicates E-<:tlp Location from top of Jet Needle
Alt.
Met(Ft)
0.900
(D-3000)
·20' to
+10'F
-29•to
·t2'C
+10'to
+40' F
-12• to +5' C
Above
+40"F
AboVe5 ' C
350
'340
320
112
300
112
300
#2
280
#2
260
lt2
112
901).1800
(3000.6000)
320
310
lt2
112
tS00.2700
290
280
#2
270
270
260
#2
250
240
112
112
(6001).9000)
2700.3700
~12000)
Polaris Industries Inc.
Below
-20'F
Below
·29'C
1/2
112
il2
5.15n
112
9/97
FUEL SYSTEM/CARBURETION
1998 Jetting Compensation Charts
700 XC
SN70-70LCDCSP-02
Kelhin PWK 39
MainJet-185 Long Hex
Pilot Jet - 38
Cut Away - 6.0
Air Screw- 1 Turn
Jet Needle - R1368G-3
Needle Jet- 2.9mm Fixed
700 XCR
EC68PL060
VM38
Main Jet - 380
Pilot Jet- 50
Cut Away - 3.0
Air Screw- 1.0 Turn
Jet Needle - 6CEY6-4
Needle Jet- Q-2 (247)
700 RMK
SN70-70LCDCSP-01
Keihin PWK 39
MainJet-158 Long Hex
Pilot Jet - 42
Cut Away - 5.5
Air Screw - 1 Turn
Jet Needle - R1371 G-3
Needle Jet- 2.9mm Fixed
AMBIENT TEMPERATURE
# Indicates E-cllp Location from top of Jet Needle
All
Mat.(Ft)
Below
-20' F
Below
-29'C
-20' to
t10'F
-29'10
-12' C
t10' to
t 40' F
-12' to +5'C
Above
t40' F
Above 5' C
D-900
(D-30001
190
#3
"185
#3
178
#3
172
SOD-1800
(300()-8000)
178
#3
176
#3
168
#3
162
lSOD-2700
(BOOD-9000)
170
#3
165
#3
158
#2
155
270()-3700
(9000-12000)
t58
#3
165
#2
150
#2
145
#2
#3
113
112
AMBIENT TEMPERATURE
# Indicates E-cllp Location from top of Jet Needle
Alt.
Met.(Ft)
Below
-20' F
Below
-29' C
-20"to
t10' F
-29' 10
-12' C
t10' to
t4D' F
-1'2' to +5 C
Above
t40' F
Above 5' C
D-900
(D-3000)
400
#4
'380
#4
360
#3
340
#3
90()-1800
(300D-8000)
370
#4
350
#3
330
#3
310
#2
180D-2700
(600D-9000)
340
#3
320
#3
300
#2
280
#2
270()-3700
(9000-12000)
310
290
#2
270
250
#1
#3
112
AMBIENT TEMPERATURE
# Indicates E-chp Location !rom lop of Jet Needle
Alt.
Met.(Ft)
0-900
(D-3000)
Below
-20' F
Below
-29' C
/
-20' to
t10'F
-29' 10 -12' C
+10'to
t40'F
+5°C
~12 ° to
Above
t40'F
Above s• c
'J~/• l?/t1)~:/
/,::; %/ ;,:;.]%
~
~Vid
~:·
, .?
·/"
r'l
:;;'
90D-t800
(300()-8000)
178
175
#3
#3
180()-2700
(600()-9000)
168
270D-3700
(ecoo-12000)
165
#3
162
#3
162
#3
158'
152
#3
11'2
158
#3
165
#3
148
#2
145
#3
#2
[_,/ / / ,.j · Shaded ~one should tUm A1r Screw to 1/4 turn.
AMBIENT TEMPERATURE
(PTOICENTERIMAG)
# Indicates E-cl1p Location from lop of Jet Needle
Storm
EC80PL052
VM38
Alt.
Mel.(Ft)
Below -20•F
Bet ow
-29" C
-20" to
+10" F
-29°10
-12·c
-12° to .soc
+10'tO
+40"F
Above
+40• F
Above 5' C
0-900
(D-30001
430/4201440
#3
41 Q/400'420
39013801400
37013601380
#3
90D-1800
(300D-8000)
3801370/390
#3
3601350/370
#3
340/3301350
#3
320/310/330
#2
180()-2700
(8000-9000)
3401330/350
#3
320/310030
#3
3001290131 0
#2
290/280/300
#2
270()-3700
(9000-12000)
2901280/300
#3
270126012ll0
#2
250/2401260
2401230/250
#2
PTO- CEN - MAG
MainJet-41 0-400-420
Pilot Jet - 50
Cut Away - 3.0 CH
Air Screw - 1.0 Turn
Jet Needle - 6CGY6-3
Needle Jet- Q-0 (247)
'#3
#3
112
Maln jets listed left to rlghl - PTO-Center-Mag
9/97
5. 150
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Gasoline Volatility
Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.
A
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored or used.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothIng.
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
Explanation of Gasoline Volatility
In order for an engine to start easily and run properly, gasoline must be able to burn without causing detonation,
vapor lock, flooding, or icing of fuel lines, fuel pumps, or carburetors. One of the sometimes misunderstood properties of gasoline is its volatility, or ability to vaporize at different ambient temperatures and altitudes during the
year.
When gasoline is blended, it is given a Reid Vapor Pressure (RVP) number which reflects its ability to vaporize
or mix with air at a given temperature range. Gasoline vapor pressure is measured by putting a sample of fuel
inside a closed container and applying a specified amount of heat to the container for a certain amount of time.
This pressure will vary from about 7.0 PSI during the summer to approximately 13.5 PSI during the colder months.
Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year.
When the weather is very cold, gasoline must be able to atomize very quickly in order for an engine to start and
warm up properly. If summer blend fuel, which has a low Reid Vapor number, is being used, little or no vaporization
will occur. Droplets will form causing flooding and very hard starting.
If winter blend fuel is being used during the summer months, it may cause vapor lock (boiling fuel) inside the fuel
lines, fuel pump, or carburetor. This will cause warm engine driveability problems and hard starting when warm.
Some states are limiting the Reid Vapor number to 9.0 PSI year around to help meet evaporative emissions standards.
Warm Weather
Low Vaporization Rate
Maximum Reid Vapor
Cold Weather
11/95
Ambient Air Temp. Range
Class
Pressure
Low
High
A
7.0 PSI
60° F
11 oo F +
B
9.0 PSI
50° F
110° F
c
10.5 PSI
40° F
9JCF
D
12.0 PSI
30° F
85° F
E
13.5 PSI
20° F
69° F
Add 2.4° F for each 1000 feet above seal level.
5.16
High Vaporization Rate
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Systems
Float Chamber Venting
Fuel flows through a carburetor by creating a pressure difference between the venturi and the float bowl. The
greater the pressure difference, the greater the fuel flow. On some models the float bowl is vented to the handlebars. This provides consistent atmospheric pressure for a consistent fuel flow. If the vent lines become kinked,
plugged, or exposed to fluctuating pressures (under hood) the pressure difference will change, causing erratic
fuel flow.
Polaris has introduced airbox venting on some models. The vent lines are connected to a baffle inside the airbox.
This provides a more consistent pressure difference between the carburetor venturi and the float bowl as the vacuum inside the airbox changes. For example, if the airbox foam filter becomes plugged with snow when riding
in powder, the airbox vacuum increases. Without airbox venting, the pressure difference would increase substantially, choking or flooding the engine. With airbox venting, the pressure difference remains the same, creating
a leaner mixture to compensate for reduced air flow.
Vent Line Routing
(Opposite Carb to Handlebar)
Tee Fitting ---=:::;;~.,.---JI
One Way
Check Valve
Drain Hose
\--~-ij---
--~J Flow
Atmospheric
Pressure
Direction
Through
Valve
Some Models Have
Interconnecting Lines Between each Carb
-V
Tee Fittings Are
Orientated Vertically
1_ 1
~
$
Air Box
Some models have airbox venting
Polaris Industries Inc.
5.17
~
11/95
FUEL SYSTEM/CARBURETION
Fuel Delivery System - Typical
The fuel system contains many components which directly affect fuel mixture and driveability. When performing
diagnosis or carburetor maintenance, the entire fuel delivery system should be inspected. The illustration below
shows parts of the system requiring periodic maintenance to ensure there is no fuel or air leaks present.
Fuel filters should be replaced at least once per season or more often if any contamination is suspected.
Fuel lines should be replaced every other season or more often if they become brittle or swollen. Fittings should
be inspected at that time for cracks or leaks.
Test run and check the fuel system for leaks any time parts are replaced . Verify that all lines are routed correctly
away from any moving parts.
I
Vent Lines
Carb Mounts
Cylinder
Base
Gasket
Crank
Seal
Weighted Pickup
and Line
Fuel Hose - Indy Storm/SKS/RMK
The Storm fuel system incorporates dual fuel pumps. It is important to pay particular attention to correct routing
of the fuel lines in order to provide an adequate fuel supply to the engine.
Fuel Shut
Off Valve
Vacuum/
Impulse
Line
To Carburetors
11/95
5.18
Polaris Industries Inc.
-
FUEL SYSTEM/CARBURETION
Starter System - Closed Throttle
Mikuni carburetors use a starter system rather than a choke. In this type of carburetor, fuel and air for starting
the eng;ne are metered with entirely independent jets. The fuel metered in the starter jet is mixed with air and
is broken into tiny particles in the emulsion tube. The mixture then flows into the plunger area, mixes again with
air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle
in the optimum air/fuel ratio. The starter is opened and closed by means of the starter plunger. The starter type
carburetor is constructed to utilize the negative pressure of the inlet pipe, so it is important that the throttle valve
is closed when starting the engine.
---- -- --~-------------1
r r-- -- ---~ -------- ----~
II
II
I I
II
IQ
Cable Adjuster
11
II
1I
II
I
~I
II
II
l~
I ~- ~-,______,
I 1
I I
: I
Cable Adjuster Lock Nut
Plunger Spring
Plunger Cap
1I
I
1
l'ffF=~
I
Throttle Valve
Starter Plunger
Inlet Starter
Inlet Bleed Air
Starter Jet
Polaris Industries Inc.
5.19
11/95
FUEL SYSTEM/CARBURETION
Pilot System (0-3/8 Throttle)
The pilot system's main function is to meter fuel at idle and low speed driving. Though its main function is to supply
fuel at low speed, it does feed fuel continuously throughout the entire operating range.
Fuel for the pilot jet is drawn from the float bowl, mixed with air regulated by the air screw, and delivered to the
engine through the pilot outlet.
The mixture is regulated to some degree by adjusting the air screw. When the air screw is closed, the fuel mixture
is made richer as the amount of air is reduced. When the air screw is opened , the mixture is made more lean
as the amount of air is increased.
Throttle Valve
Throttle Stop Screw
r • :::::=l===~~
...,..
'--~.---..:::::a
1
I
II
I
11/95
5.20
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Slide Cutaway (1/8-3/8 Throttle)
Throttle valve cutaway effect is most noticeable at 1/4 throttle opening. The amount of cutaway is pre-determined
for a given engine to maintain a 14:1 air/fuel ratio at part throttle. A steep angle would indicate a fairly lean mixture
because there is less resistance to air flow. A flat angle would provide a much richer mixture because there is
more resistance to air flow. The venturi shape can be adjusted for each engine's breathing characteristics by
using a different valve cutaway angle. A number will be stamped into the bottom of the valve (e.g. 2.5) indicating
the size of the cutaway. The higher the number, the steeper the angle.
Cutaway Angle
Throttle Valve
Air Jet
By-pass
Pilot Outlet
Pilot Jet
Needle Jet
Main Jet
3.0
1.5
Leaner
Polaris Industries Inc.
Richer
5.21
11/95
FUEL SYSTEM/CARBURETION
Jet Needle/Needle Jet (3/8-3/4 Throttle)
The jet needle and needle jet have the most effect between 3/8 and 3/4 throttle opening. Some mixture adjustment can be accomplished by changing the location of the "E" clip on the needle. Moving the clip down raises
the needle in the jet passage and richens the mixture. Moving the clip up lowers the needle in the jet passage
and leans the mixture . Letter and number codes are stamped into the needle and the jet indicating sizes and
tapers of each.
Clip Position
Throttle Valve
Jet Needle
Air Jet
By-pass
Pilot Outlet
Pilot Jet
Needle Jet
Main Jet
11/95
5.22
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Main System (3/4 to Full Throttle}
The main system is designed for delivering fuel between low speed and high speed operation. This system is
made up of the jet needle, needle jet, and main jet. The main system begins to take effect as soon as there is
enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly. This
system works in conjunction with the needle jet system.
During low speed driving, there Is very little clearance between the jet needle and the needle jet; therefore, very
little fuel from the main jet can pass between the jet needle and the needle jet. As the throttle valve opening is
increased, the tapered jet needle is raised farther out of the needle jet, allowing greater fuel flow. Under full throttle
opening, the cross sectioned area of clearance between the jet needle and the needle jet becomes greater than
the cross sectioned area of the main jet. Thus the main jet is now controlling the amount of fuel flow.
Throttle Valve
Jet Needle
Air Jet
By-pass
Pilot Outlet
Pilot Jet
Main Jet
Polaris Industries Inc.
5.23
11 /95
FUEL SYSTEM/CARBURETION
Function
The function of a carburetor is to produce a combustible air/fuel mixture by breaking fuel into tiny
particles in the form of vapor, to mix the fuel with
air in a proper ratio, and to deliver the mixture to
the engine. A proper ratio means an ideal air/fuel
mixture which can burn without leaving an excess
of fuel or air. Whether the proper mixture ratio is
maintained or not is the key to efficient engine operation.
The engine of a vehicle is operated under a wide
range of conditions, from idling with the throttle
valve remaining almost closed, to full load or
maximum output with the throttle valve fully
opened. In order to meet the requirements for the
proper mixture ratio under these varying conditions, a low speed fuel system, or pilot system,
and a main fuel system are provided in Mikuni VM
type carburetors.
Float Guide Pin
The Mlkuni carburetor has varying operations depending upon varying driving conditions. It is
constructed of a float system , pilot system, main
system, and starter system or initial starting device.
Float System
Float
The float system is designed to maintain a
constant height of gasoline during operation.
When the fuel flowing from the fuel pump into the
float chamber through the needle valve reaches
the constant fuel level, the floats rise. When the
buoyancy of the float and the fuel pressure of the
fuel pump balance, the needle valve sticks fast to
the needle seat, preventing further delivery of
gasoline, thereby holding the standard level of
gasoline.
The fuel level in the bowl assists in controlling the
amount of fuel in the fuel mixture. Too high a level
allows more fuel than necessary to leave the
nozzle, enriching the mixture. Too low a level results in a leaner mixture, since not enough fuel
leaves the nozzle. Therefore, the predetermined
fuel level should not be changed arbitrarily.
11/95
5.24
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Component Functions
Pilot Jet
From idling to low speeds, the fuel supply is metered by the
pilot jet. There are several air bleed openings in the sides
of the pilot jet which reduce the fuel to mist. The number
stamped on the jet is an indication of the amount of fuel in
cc's which passes through the jet during a one minute interval under a given set of conditions.
Indicator
Number
Pilot Air Screw
The pilot air screw controls the fuel mixture from idle to low
speeds. The tapered tip of the air screw projects into the air
passage leading to the pilot jet air bleeds. By turning the
screw in or out, the cross sectional area of the air passage
is varied, in turn varying the pilot jet air supply and changing
the mixture ratio.
Pilot Air Screw
/
~
Air/Fuel Mixture Ratio
A carburetor with a piston type throttle valve is also called
a variable venturi type carburetor. In this type of carburetor,
the needle jet and jet needle serve to control a proper air/
fuel mixture ratio at the medium throttle valve opening (between 1/4 and 3/4 opening). Having the proper needle jet
and jet needle has a major impact on engine performance
at partial load.
The jet needle tapers off at one end and the clearance between the jet needle and the needle jet increases as the
throttle valve opening gets wider. The air/fuel mixture ratio
Is controlled by the height of the "E" ring inserted into one
of the five slots provided in the head of the jet needle. The
chart at right shows the variation of fuel flow based on the
height of the "E" ring.
..r-
2
-3
~4
4
~
;:::
~
~
15
50
75
100%
Throttle Valve Opening
Polaris Industries Inc.
5.25
11/95
FUEL SYSTEM/CARBURETION
Component Functions
Jet Needle
The jet needle has five adjustment grooves cut into the upper portion, and is tapered from approximately the middle
of the needle to the lower end. The top is fixed to the center
of the throttle valve by the needle clip, and the tapered end
extends into the needle jet. Fuel flows through the space
between the needle jet and jet needle. This space does not
vary until the throttle reaches the 1/4 open point. At that
time the tapered portion of the needle begins to move out
of the jet, affecting fuel flow as the opening enlarges. If the
needle clip is changed from the standard position to a lower
groove, the needle taper starts coming out of the jet sooner,
resulting in a richer mixture. Moving the clip higher produces a leaner mixture. If the taper is worn due to vibration,
fuel flow may be significantly affected.
Leaner
1
3 Groove
5
t
Richer
Needle Jet
The needle jet works in conjunction with the jet needle to
regulate fuel flow rate. An air bleed opening in the side of
the needle jet brings in air measured by the air jet. This air
initiates the mixing and atomizing process inside the needle
jet. Mixing is augmented by a projection at the needle jet
outlet, called the primary choke. The letter number code
stamped on the jet indicates jet inside diameter.
I
=I
D
Throttle Opening vs. Fuel Flow
In a full throttle condition the cross sectioned area between the jet needle and the needle jet is larger than
the cross sectioned area of the main jet. The main jet
therefore has greater control over fuel flow.
Large
Clearance
Closed
Throttle
11/95
5.26
One-half
Throttle
Full
Throttle
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Component Functions
Throttle Valve
The throttle valve controls the rate of engine air intake
by moving up and down inside the main bore. At small
throttle openings, air flow control is performed chiefly
by the cutaway. By controlling air flow the negative
pressure over the needle valve is regulated, in turn
varying the fuel flow.
I
I
~__i
The throttle valves are numbered 1.0, 1.5, 2.0, etc.,
according to the size of the cutaway. The higher the
number, the leaner the gasoline/air mixture.
Cutaway
+
Mikuni Main Jet
When the throttle opening becomes greater and the
area between the needle jet and jet needle increases ,
fuel flow is metered by the main jet. The number on the
jet indicates the amount of fuel CCs which will pass
through it in one minute under controlled conditions.
Larger numbers give a greater flow, resulting in a
richer mixture.
Round
Hex
Main jets are screwed directly into the needle jet base.
Keihin Main Jet
The number on the Keihin (Round) main jet corresponds to the diameter of the metering orifice.
Polaris Industries Inc.
5.27
9/96
FUEL SYSTEM/CARBURETION
Component Effect vs Throttle Opening
The throttle opening chart below demonstrates component relationship to fuel flow versus throttle valve opening.
The pilot system's main function is that of a low speed jet. Its most effective range of fuel delivery is from idle
to approximately 3/8 throttle valve opening.
The throttle valve controls the rate of engine air by its movement up and down in the carburetor venturi. At small
throttle openings the air flow is regulated chiefly by the valve cutaway, with greatest effectiveness at 1/4 throttle
opening. Throttle valves are numbered 1.0, 1.5, 2.0, etc., according to the size of the cutaway. Decreasing the
cutaway number will increase the amount of fuel delivered in its effective range .
The jet needle and needle jet have an effective operating range from approximately 1/8 to 7/8 throttle opening.
The amount of fuel delivered during this range relies upon the jet needle clip position, as well as the needle jet
size and other specifications.
The main jet affects fuel delivery at 1/4 throttle and consistently increases to full throttle opening.
z
(i)
<(
w
a:
0
~
EFFECT
I
"z
I
(i)
I
I
I
I
I
I
<(
w
a:
0
w
c
I
0
1/4
3/8
1/2
5/8
3/4
7/8
FULL
THROTTLE OPENING
Throttle Valve Cut-Away
Jet Needle/Needle Jet
11/95
5.28
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Jetting Guidelines
Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for
combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher
temperatures, the air is less dense.
Carburetors on most Polaris models are calibrated for an altitude of 0-3000 ft (0-900 meters) and ambient temperatures between -20° to+ 1oo F (-29° to -12° C). All carburetors must be re-calibrated if operated outside the production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or
temperatures.
A main jet that Is too small will cause a lean operating condition and may cause serious engine damage.
Jet the carburetors carefully for elevation and temperature according to the jetting charts In this manual,
the specification decal on the hood, or the jetting charts In the Owner's Safety and Maintenance Manual
for each particular model. See additional information regarding the use of oxygenated fuels on following
page.
NOTE: It is the dealer's responsibility to ensure that the correct jets are installed in the machine for a geographical
area. Be very careful when jetting down in warm weather. As the weather turns colder it will be necessary to re-jet
upward to prevent engine damage. When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered.
Polaris Industries Inc.
5.29
11/95
FUEL SYSTEM/CARBURETION
Oxygenated Fuel - Carbureted Models
Oxygenated Fuel
Due to the increased emphasis on reducing auto emissions, some areas of the U.S. are required to use oxygenated fuels. Oxygenated fuels are those which include oxygen in the molecule due to the addition of an ether or
alcohol.
Oxygenated fuel containing a mixture of up to 10% ethanol can be used in all models of Polaris snowmobiles if
these guidelines are followed:
NOTE: The use of fuel containing methanol is not recommended.
On carbureted models
1. Use fuel with a minimum pump octane of 89 or higher (R+M)/2 method. NOTE: Some models are calibrated
to use a minimum of 91 octane fuel. On these models, only 91 octane or higher should be used. Refer to the
Specification Decal or Owner's Safety and Maintenance Manual for octane recommendation.
2. When using 87 octane oxygenated fuel, install main jets that are one size larger than that listed on the jetting
chart for a given altitude and temperature. For example, the minimum octane (non-oxygenated) fuel for the
1996 Indy Classic is 87. The main jet installed during production for use at altitudes of 0-3000 ft. and
temperatures between -20 and +10°F) Is a 340. To use 87 octane oxygenated fuel, install 350 main jets.
3. Turn the pilot air screws in (clockwise) 3/8 turn from the standard setting. Example: if the production air screw
setting is 1 turn out, the setting for 87 octane oxygenated fuel would be 5/8 turn out.
NOTE: The following Indy Classic charts are provided as an example only.
Indy Classic
AMBIENT TEMPERATURE
89 Octane
Oxygenated
AHitude
Meters
(Feet)
Below·20' F
Below-29' C
·20' to +10' F
-29' to -12'C
+ 10 ' 1o +40' F
-12' to +5' C
Above +40 ' F
Above +5' C
0.900
(o-3000)
360
'340
320
300
900.1800
320
300
1800-VOO
(6000-9000)
280
260
2700-3700
(9000.12000)
240
<.i ~ll
(3~)
c::J - Shaded zone should drop Jet Needle one position (raise E-Ciip)
• Production Setting
Indy Classic
AMBIENT TEMPERATURE
o-900
87 Octane
Oxygenated
Below -20' F
Below -29' C
-20• to +1O' F
-29' to -12' C
+ 1O' lo +40' F
-12· to ..
Above +40 ' F
Above +5'C
370
350
330
310
s·c
(().30QQ)
Althude
Meters
(Feet)
900-1800
(3Q00-8000)
330
1800.2700
(6000-9000)
290
270().3700
(9000.12000)
250
c::::J -Shaded zone should drop Jet Needle one position (raise E-Ciip)
11/95
5.30
Polaris Industries Inc.
..__/
FUEL SYSTEM/CARBURETION
Oxygenated Fuel - EFI Models
Oxygenated Fuel
To use 87 octane oxygenated fuel on EFI models:
1.
At altitudes below 5000 ft., the compression ratio must be reduced by installing .020" head gasket shims
between the cylinder head gasket and cylinder head. The part numbers are shown below. No change is
required if machine is operated at altitudes above 5000 feet (1500 meters).
EFI Cylinder Head Shims
Model
Shim Part Number
500 EFI/SKS/RMK
(1) 5211416
RXL
(3) 5211414
Fuel System Deicers
If non-oxygenated fuel is being used, Polaris recommends the regular use of Isopropyl base fuel system deicer
(Polaris PN 2870505) . Add 1 to 2 ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage
resulting from fuel system icing and lean mixtures. Never use deicers or additives that contain methanol. Use
only isopropyl fuel system deicers.
If using oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives are not required and should not be used.
Whenever servicing the carburetor or fuel system, it is important to heed the warnings found on page 5.1.
Polaris Industries Inc.
5.31
11/95
FUEL SYSTEM/CARBURETION
ACCS System
1996 To Current Altitude Compensatin g Carburetor System (ACCS)
The Altitude Compensating Carburetor System (ACCS) is designed to automatically compensate for changes
in altitude. This allows the snowmobile to operate in changing elevations without having to change jets, although
extreme temperatures may require re-jetting for optimum performance. Refer to the jetting compensation chart
on page 5.15f. The 1996 ACC System compensates for both high speed and low speed changes, eliminating
the need to adjust air screws. On 1997 ACCS models, the air screw is adjustable.
A vacuum line is con nected to the float bowl.
The ACCS valve is connected to this line via
the 4-way manifold. At low altitude the ACCS
valve supplies atmospheric pressure to the
vacuum line and the float bowl (see Ill. 1).
High Atmospheric Pressure• Bellows compress
• Fuel flow increases
To Float Bowls
This
end
fixed
Low Altitude I High
Atmospheric Pressure
1996 to Current ACCS System
At high altitudes the bellows expand, moving
the plunger to the left and closing off some of
the passageways through the ACCS valve
(see Ill. 2) . This prevents atmospheric pressure from reaching the float bowl, allowing the
vacu um line to reduce the pressure in the float
bowl. This reduces the amount of fuel supplied through the carburetor, preventing the
mixture from becoming too rich .
Ill. 1
Low Atmospheric Pressure• Bellows expand
• Fuel flow decreases
Vacuum from
Venturi
To Float Bowls
~~
~
This
end
fixed
-:unger
1\
Hig h Altitude I Low
Atmospheric Pressure
1996 to Current ACCS System
9196
5.32
Ill. 2
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
ACCS System
Altitude Compensating Carburetor System (Cont.)
NOTE: The 1997 to current ACCS models
are equipped with air screws to adjust the low
speed (pilot) air/fuel mixture.
Another feature of the 1996 ACC System
automatically adjusts the slow (pilot) air system passageways. This feature serves the
same function as an air screw on a standard
carburetor system.
......__....
A spring loaded plunger is located inside the
valve. At low altitude, the spring pushes the
plunger into a closed position (see Ill. 3).
ACCS Valve Operation
Vacuum
Float Bowl
Pilotair~ ~
waymanif~d~--~
~
9 ti. --~
Low Altitude I
Atmospheric Pressure
1996 ACCS Only
In Ill. 4, the bellows has moved the primary
plunger to the left, engaging the secondary
plunger and removing it from its seat. Atmospheric pressure is now being supplied to the
pilot air jet, supplementing the air flow in the
secondary slow air system and making the
fuel mixture leaner to compensate for the thinner air at high altitudes.
Ill. 3
ACCS Valve Operation
Vacuum
Float Bowl
Pilot air jet to 3
way manifold
'\
~*------=====-~
IiI
High A:titude I
Atmospheric Pressure
1996 ACCS Only
Polaris Industries Inc.
5.33
Ill. 4
9/96
FUEL SYSTEM/CARBURETION
ACCS System
ACCS System
Air Box
ACCS 4-way
Manifoldmounted to
air box
ACCS
-- _Valve
-
Vent line
attachment to
handlebars
4 Way Manifold I Float
Bowl Vent Control
_ - - - ACCS 3-way
Manifold- mounted
4 way manifold
(
3-way Manifold -,
attachment (1996',
ACCS Only)
PTO
Carb
4-way
Manifold
attachment
A
-=-c,...-c-=-s=-v
- a- lv
- e--.1
Center
Carb
M C b
ag ar
1r -
Vent line attachment
to handlebars
3 Way Manifold I
Pilot Air Control
(1996 ACCS Only)
1996 ACCS
Only
NOTE: There is only one ACCS valve. The illustration above has been
divided to show the separation of systems. See page 5.7a for line connections.
9/96
5.34
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Mikuni Carburetor Service
Carburetor Removal, Disassembly, and Inspection (Typical)
Typical VM 38 Shown. Refer to exploded views on pages
5.4- 5. ?a for other types.
1 . Remove carburetor from
engine.
Before
disassembling, clean outside of carburetor thoroughly
with solvent.
Do not use compressed air to dry at this time. The float
chamber could become pressurized resulting in damage to
the floats or inlet needle and seat..
2.
Remove slide valve. Inspect for nicks or burrs which
may cause sticking.
3.
Remove jet needle by compressing return spring
toward top cap and removing throttle plate which rests
on top of needle "E" clip. Note the "E" clip position and
inspect needle taper for wear. An indication of wear
would be an hourglass shape or polished spots
somewhere along the taper.
Cap ----e.1J
Gasket--~
~
i:?'
Spring
-"E"
cnp
Slide Valve
4.
5.
Remove choke plunger. Check condi tion of seal on tip
of plunger. Any nicks or cuts will cause leakage and a
rich fuel condition , usually most evident at idle and low
speeds. Inspect the plunger seat for damage or foreign
material.
Check choke cable movement. Plungers and springs
should move back and forth freely.
/
Retainer Plate
----V
---e
Jet Needle
Spring"'--~
~~
Plunger Seat
Polaris Industries Inc.
5.35
9/96
FUEL SYSTEM/CARBURETION
Mikuni Carburetor Service
Carburetor Disassembly and Inspection Cont.
6.
Remove water trap assembly from float bowl and inspect
0-ring, hose and clamp condition. Refer to exploded
view corresponding with carburetor being serviced.
q;r,..........- Trap Nut
~
H
ose
7.
Inspect choke fuel
obstruction.
8.
Use an automatic center punch to remove float arm pin.
Remove inlet needle and seat assembly.
9.
Inspect needle for wear and replace sealing washers
upon reassembly.
Clamp
~~~
~/
Drain Plug
supply passage in bowl for
.------:;:o
CAUTION!'
I
Do not bend float arm during disassembly. Do not use excessive force to remove float arm pin. The float pin tower castings are very easily damaged and are not repairable.
9/96
5.36
0
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Mikuni Carburetor Service
Carburetor Disassembly and Inspection Cont.
10. Remove main jet and washer (or spacer ring) and push
needle jet into the slide valve chamber to remove. Clean
air bleed hole in needle jet.
11 . Remove pilot jet.
I
CAUTtON! j
Wear eye protection when using compressed air or cleaning
solvents. Review all fuel system warnings found on page 5.1
before proceeding.
12. Remove pilot air screw and clean all passages in the
carburetor body with carburetor cleaner.
Dry all
passages and jets with compressed air. Replace
gaskets and any parts which show wear or damage.
13. Reassemble carburetor, adjusting float level before
installing float bowl.
Refer to page 5.38 for float level adjustment and leak testing
procedures.
Polaris Industries Inc.
5.37
9/96
FUEL SYSTEM/CARBURETION
Mikuni Carburetor Adjustments
Float Level Adjustment
1. Remove float bowl.
2.
With carburetor in an inverted position, float arm (A)
should be parallel with body (B). See illustration at
right. Arms must be parallel to each other.
3.
To adjust float arm, bend tang contacting inlet needle.
Never bend the float arm itself.
Leak Testing Needle and Seat
1.
After adjustment of float level, with carburetor still in an
inverted position, install float chamber and connect
pressure tester PN 2870975 to fuel inlet fitting.
2.
Apply approximately 5 PSI pressure and wait for one
minute. The needle and seat should hold pressure
indefinitely. If the pressure drops rapidly replace the
needle and seat assembly and/or sealing washers.
-
9/96
5.38
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Keihin Carburetor Service
Carburetor Removal, Disassembly, and Inspection
1.
Remove
carburetor from
engine.
Before
disassembling, clean outside of carburetor thoroughly
with solvent.
CAUTION:
I
Do not use compressed air to dry at this time. The float
chamber could become pressurized resulting in damage to
the floats or inlet needle and seat. Do not soak Keihin carburetors in carb cleaner. Clean only with aerosol cleaner.
2.
Remove slide valve. Inspect for nicks or burrs which
may cause sticking.
3.
Remove jet needle by compressing return spring
toward top cap and removing throttle cable.
Disconnect cable holder and remove jet needle. Note
"E" clip position and inspect needle taper for wear. An
indication of wear would be an hourglass shape or
polished spots somewhere along the taper.
4. Remove choke plunger. Check condition of seal on tip
of plunger. Any nicks or cuts will cause leakage and a
rich fuel condition, usually most evident at idle and low
speeds. Inspect the plunger seat for damage or foreign
material.
5.
Check choke cable movement. Plungers and springs
should move back and forth freely.
Spring"-..~
~-----Plunger Seat
Polaris Industries Inc.
5.38a
9/96
FUEL SYSTEM/CARBURETION
Keihin Carburetor Service
Disassembly Cont.
6.
Remove water trap assembly from float bowl and inspect
0-ring, hose and clamp condition. Refer to exploded
view corresponding with carburetor being serviced.
09!_........... Trap Nut
Llf
I
~
I
Hose...._
n
~
t/
Clamp
DrainPiug
'---'
7.
Inspect choke fuel supply passage as shown for
obstruction.
8.
Remove float arm pin. Remove inlet needle. NOTE:
Seat assembly is not replaceable. DO NOT remove.
9.
Inspect needle for wear.
Do not bend float arm during disassembly. Do not use excessive force to remove float arm pin. The float pin tower castings are very easily damaged and are not repairable.
9/96
5.38b
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Keihin Carburetor Service
Carburetor Disassembly Cont.
10. Remove main jet.
11 . Remove pilot jet.
Wear eye protection when using compressed air or cleaning
solvents. Review all fuel system warnings found on page 5.1
before proceeding.
12. Remove pilot air screw and clean all passages in the
Dry all
carburetor body with carburetor cleaner.
passages and jets with compressed air. Replace
gaskets and any parts which show wear or damage.
Polaris Industries Inc.
5.38c
9/96
FUEL SYSTEM/CARBURETION
Keihin Carburetor Service
Carburetor Assembly
1.
Install pilot jet and main jet.
2.
Install inlet needle and float assembly.
3.
Hold carburetor at angle shown so needle spring is not
compressed. Measure from gasket surface of carb
body to highest point on float. Measurement should be
within specification.
4.
To adjust float level, bend tang contacting inlet needle.
See photo above.
Adjust float with tange ohly
Do not bend float arm. Adjustment should be made with
tang contacting inlet needle.
9/96
5.38d
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Keihin Carburetor Service
\_.t
5.
After adjusting float level, place carburetor in an
inverted position.
6.
Connect pressure tester to fuel inlet fitting. Apply 5 psi
pressure and observe for one minute. The needle and
seat should hold pressure indefinitely. If the pressure
drops, carefully inspect the needle and the needle
seat. The needle can be replaced if necessary. The
needle seat cannot be replaced. If the seat surface is
damaged replace the carburetor.
Pressure Tester PN 2870975
'-
7.
Carefully inspect float bowl gasket and replace it
necessary. Install float bowl on carburetor.
8.
Install idle screw and air adjusting screw.
9. Install jet needle clip onto needle jet.
10. Install jet needle into throttle valve.
11. Screw cable holder into throttle valve to secure jet
needle and throttle valve.
12. Inspect gasket under throttle cap. Install throttle cable,
spring, and coilar. Connect cable to slide valve.
13. Install carburetor top cap until seated on carburetor
body.
Polaris Industries Inc.
5.38e
9/97
FUEL SYSTEM/CARBURETION
Adjustments
1996 Throttle Gap Chart
Model
Engine Model
Throttle
Gap Under
Cutaway
Air
Screw
ccw
Idle
RPM
From
Seat
Lite, Lite GT, Lite Deluxe
EC34-2PM02
.240"/6.1 mm
1.5
1600
Sport. Transport, Sport Tounng
EC44-3PM01
.236./6.0mm
1.25
1800
Super Sport
EC44-3PM02
.200"/5.1 mm
1.25
1600
1.5
1600
440
EC45PL02/06
.21 0"/5.3mm
440 XCR
EC45PL07
.210"/5.3mm
1.0
1800
440 XCR SP
EC45PL08
.210"/5.3mm
1.0
2000
WideTrakGT
EC50PM03
.240"/6.1mm
1.0
1600
Trail, Trail Touring
EC50PM04/E04
.240"/6. 1mm
1.5
1600
500,500 SKS
EC50PL11
.21 0"/5.3mm
1.0
1600
Classic
EC50PLE11
.210"/5.3mm
1.0
1900
WideTrak LX
EC50PL 12
.240./6.1 mm
1.5
1600
Classic Touring
EC50PL14
.240"'/6.1 mm
1.5
1600
500 RMK
ECSOPL 15
.21 0"/5.3mm
1.0
1600
XLT SP, 600 XCR
EC58PL02
.221"/5.6mm
1.0
2000
XLT, XLT SKS
EC58PL03
.193"/4.9mm
1.0
1700
XLT Touring
EC58PLE05
.230"/5.8mm
1.0
1700
XLT RMK
EC58PL07
.193"/4.9mm
ACCS
1700
600 XCR SP
EC59PL01
.187"/4.8mm
1.5
2000
Ultra SP, Ultra SKS
EC68PL01
.187"/4.8mm
1.0
1500
Ultra RMK
EC68PL04
.250"/6.4mm
1.0
1800
Storm RMK
EC80PL04
.218"/5.5mm
1.0
1600
Storm, Storm SKS
EC80PL05
.218"/5.5mm
1.0
1600
9/97
5.38f
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Throttle Gap Specifications
1997 Throttle Gap Chart
1997 Model
Engine Model
Throttle Gap-Under
Cutaway
(Under front of slide
on Keihln)
Drill Size (lnches/mm)
Idle Sync. Gap
(Under Cutaway)
Air
Screw
Drill Size (lnches/mm)
(Turns)
1.5
1600
Lite, Lite GT, Ute Deluxe
EC34-2PM02
.21 g• -7/32(5.55mm)
.240" -8(6.1 Omm)
Idle
RPM
Sport, Sport Trng, Transport, XCF
EC44-3PM02
.180"-15(4 .57mm)
.200"-8(5.1 Omm)
1.0
1600
440XC
EC45PLOB
.1 72"-11 /64(4.37mm)
.190"-12(4.80mm)
.75
1600
440
EC45PL09
.1 90" -12( 4.80mm)
.21 0" -8(5.30mm)
.75
1600
440 XCR
SN44LCDCSP-01
.172"-11 f64(4.37mm)
.190"-12(4.80mm)
1.0
1800
WideTrak GT
EC50PM 03
.219"-7/32(5.55mm)
.240"-8(6.1 Omm)
1.0
1600
Trail, Trail Touring
EC50PM04
.219"-7/32(5.55mm)
.240"-8(6.1 Omm)
1.5
1600
Trail RMK
EC50PM05
.219"-7/32(5.55mm)
.240"-8(6.1 Omm)
1.0
1600
Super Sport
EC50PM06
.1 80"-15(4.57mm)
.200"-8(5.1 Omm)
1.0
1600
500, 500 Classic, 500 SKS
EC50PL17
.190"-12(4 .80mm)
.21 0"-4(5.30mm)
1.0
1600
500 RMK
EC50PL16
.21 0"-4(5.3mm)
.228"-1(5.80mm)
.75
1600
Classic Touring
EC50PL19
.219"-7/32(5.55mm)
.240"-8 (6.1 Omm)
1.0
1600
WideTrak LX
EC50PL20
.219"-7/32(5.55mm)
.240"-8(6.10mm)
0.5
1600
XLT, XLT SKS
EC58PL03
.172"- 11f64(4.37mm)
.193"-11 (4.90mm)
1.0
1700
XLTRMK
EC58PL07
.172"-11/64(4.37mm)
.193"-11 (4.90m m)
.75
1700
600 XC
EC58PL08
.172"-11 /64(4.37mm)
.190"-12(4.80mm)
.75
1700
Special Tool
Requ ired
XLT LTD, XLTTouring
EC58PL09
.21 0"-4 (5.3mm)
.228"-1 (5.80mm)
1.0
1600
XLT SP, XLT LTD SP
EC58PL12
.166"- 19(4.22mm)
.18?H-3/16(4.75mm)
1.0
1600
600 XCR, 600 XCR SE
EC59PL01
.166"-19(4.22mm)
.187"-3/1 6(4.75mm)
0.5
1600
Ultra, Ultra Touring, Ultra SP
EC68PL01
.1 66"-19(4.22mm)
.187'"-3f16(4.75mm)
1.0
1800
Ultra SPX, Ultra SPX SE
EC68PL03
.228"-1 (5.79mm)
.248'"-1/4 (6 .30mm)
1.0
1800
700 SKS, 700 XC
SN70LCDCSP-Q1
.031 "-1 /32(0.79mm) •
.0469"-3/64(1 .19mm)"
1.0
1500
PN2871810
700 RMK
SN70LCDCSP-Q2
.078"-5/64(1.9Bmmr
.0937"-3/32(2.38mm) •
1.5
1500
PN2871811
Storm RMK
EC80PL04
.228"- 1(5.79mm)
.248"-1/4(6.30mm)
1.0
1600
.228"-1(5.79mm)
.248" -1/4(6.30mm)
1.0
1600
Storm, Storm SE
EC80PL04
• Requires Special tool with two drill gauges spaced Bmm apart. Measured on forward edge (engine side) of slide.
-.......__.
Polaris Industries Inc.
5.39
9/97
FUEL SYSTEM/CARBURETION
Throttle Gap Specifications
1998 Models
1998 Model
Engine Model
Throttle Gap-Under
Cutaway
(Front of slide on
Keihin)
Idle Sync. Gap
Under Cutaway
(Front of slide on
Keih in)
A ir
Screw
{Turns
out)
Idle
RPM
Lite Deluxe
Lite I Lite Touring
EC34-2PM02A
.219"- 7/32 {5.55mm)
.240"-lt-73 (6.1 mm)
(15/64=.2344")
1.5
1600
Sport f Sport Tour
Transport
XCF
EC44-3PM024
.180"- 1115 (4.57mm)
.200"(5. 1mm)
(#7 or 13/64")
1.0
1600
440 XCR
SN44-44LCDCSP-01
.200" - 13/64 (5.1 mm)
.217"·(5.5mm)
(7132")
1.25
1600
4401ndy
EC45PL091
_189"- #12 {4.80mm)
.208"-(5.3mm)
(lt-7 or 13/64")
.75
1600
Trail
Trail Touring
EC50PM043
.219"- 7/32 (5.55mm)
.240"- #73 (6.1mm)
(15/64}
1.0
1600
Trail RMK
EC50PM051
.219" -7/32 (5.55mm}
.240"- 1173 (6.1 mm)
(15/64}
1.0
1600
Super Sport
ECSOPM061
.180" - #15 (4.57mm}
.200"(5.1 mm)
(#7 or 13/64")
1.0
1600
500; 500 Classic
(Classic Touring)
EC50PL 171
(EC50PL191)
.219"- 7/32 (5.55mm)
.240"- #73 (6.1 mm}
(15/64)
.75
1600
500 RMK
ECSOPL161
.189"- lt12 (4.80mm)
.208"-(5.3mm)
(#7 or 13/64")
1.25
1600
XLT SP (XLT Classic)
EC50PL 140 (PL 150)
.166"- #19 (4.22mm}
.187" - 3/16" (4.8mm)
1.5
1600
Widetrak LX
ECSOPL201
.219" -7/32 (5.55mm)
.240" - 1173 (6. 1mm)
(15/64)
0.5
1600
XLT LTD
XLT Tour
EC58PL1 30
.213 f 113
5.5mm=0.2165"
.234"- A (5.94mm)
(7/32")
1.0
1600
600 XC
SN6Q.. 70LCDCSP-01
.7mm (.028")
Tool PN: 2872093
1.5mm (.059")
Tool PN: 2872093
1.0
1500
1.98mm (.078" )
Tool PN: 2871811
2.38mm (.094")
Tool PN: 2871811
0.5
600 RMK
SN6o-70LCDCSP-02
*
1500
*
600 XCR
EC59PL020
166" -#19 (4.22m m)
.187"- 3/ 16" (4.8mm)
.5
1600
Ultra
Ultra Touring
EC68PL050
.166"- #19 (4.22mm)
.187" - 3/16" (4.8mm)
1.0
1800
700 XCR
EC68PL060
.228"- 1 (5.79mm)
.248" - D (6.3mm)
(1/4")
1.0
1800
700 AMK
SN70-70LCDCSP-{) 1
.70mm (.028")
Tool PN: 2872093
1.5mm (.059")
Tool PN: 2872093
1.0
1500
SN70-70LCDCSP-D2
1.3mm (.05 1")
Tool PN: 2872092
1.60mm (.063")
Tool PN: 2872092
1.0
EC80PL052
.228" - 1 (5.79mm)
.248"- D (6.3mm)
(1/4")
1.0
700XC
Storm
Tool
*
1500
*
1600
~ Requires Special tool with two drill gauges spaced 8mm apart. Measured on forward edge (engine side) of slide.
9/97
5.39a
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Adjustments
Throttle Synchronization Procedure-1996
Mikuni Carburetors
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11 .
12.
Remove air box, noting position of throttle cable
junction block. Reposition throttle cable and junction
block in same position when air box is reinstalled.
Rotate slide valve adjustment screws (idle screw) out
(counterclockwise) approximately two turns. Loosen
throttle cable adjuster sleeve jam nuts and turn
adjuster down (clockwise) two turns.
Referring to charts on pages 5.39-5.39a, select the
correct diameter throttle gap drill gauge for the
engine.
Place drill gauge beneath slide valve cutaway as
shown in illustration at right.
Turn idle screw in until there is a slight drag on gauge.
NOTE: Drill gauge must be in center of carb bore.
This indicates proper throttle gap. Repeat procedure
on all cylinders.
Hold throttle cable junction block in same location as
noted in step #1. This is very important, since
synchronization changes if throttle cable or junction
block are improperly positioned.
With drill gauge installed under throttle slide as
shown , turn cable adjuster out (up) until the gauge
starts to move. NOTE: The drill gauge must be
centered in the carburetor bore.
Turn cable adjuster clockwise (down) 1/3 turn.
Repeat for all cylinders.
The throttle slides must raise from the idle position in
unison. Check by visually observing a drill gauge in
all carburetors, noting and comparing while lightly
depressing the throttle lever.
If adjustment is
Check throttle lever freeplay.
required, the throttle cable adjusters must be turned
equally to maintain synchronization. Tighten jam nut
while holding cable adjusters.
Check oil pump adjustment.
Reinstall air box and correctly position throttle cable
and junction block. Start engine and adjust idle stop
screws evenly until proper idle RPM is achieved.
(See chart above.) Re-check throttle lever freeplay
and reset by turning cable adjusters evenly. Tighten
cable adjuster jam nuts.
Polaris Industries Inc.
5.39b
0
Throttle Free Play (Std .) 0.010- 0.030" (.25-.76mm)
EZ Throttle 0.050- 0.060" (1.25-1.50mm)
9/97
FUEL SYSTEM/CARBURETION
Adjustments
Throttle Synchronization Procedure-1997 to
Current Mikuni and Keihin (With Idle Gap Specified)
1.
Remove air box, noting position of throttle cable
junction block. Reposition throttle cable and junction
block in same position when air box is reinstalled.
Drill gauges with 8mm ap
Throttle Cable Synchronization (Throttle Gap)
2 . Referring to chart on page 5.39a-b, select correct
diameter Throttle Gap synchronization drill gauge
for your engine.
NOTE: Keihin carburetors, require a special tool with two
drill gauges separated by an 8mm gap. See chart on page
5.39a and Illustrations at right.
3.
KEIHIN
Carburetor Synchronization Tool
Back out idle screws about three turns.
Slightly lift throttle slides with throttle lever and insert
drill gauge under throttle slide. Allow throttle slides to
return.
5. Loosen lock nut and turn throttle cable adjuster (on
top of carburetor) in (clockwise) or out
(counterclockwise) as required until a slight drag can
be felt on the gauge.
6. Securely tighten throttle cable synchronization lock
nut.
7. Repeat steps 3 through 5 on remaining carburetor.
KEIHIN
4.
Insert tool under
slide; push in until
tool body stops
against carb body
Forward
Idle Gap Synchronization
KEIHIN
8.
Referring to chart on page 5.39a, select correct
diameter Idle Gap drill gauge for the engine.
9. Slightly lift throttle slides with throttle lever and insert
idle gap drill gauge under throttle slide. Allow throttle
slides to return .
10. Turn idle adjustment screw in as required until only a
slight drag can be felt on the gauge.
11 . Repeat steps 8 through 10 for remaining cylinders.
12. Verify proper throttle lever free play and adjust if
necessary, by loosening cable adjuster locknuts and
turning adjusters out equally until throttle lever
freeplay is correct.
Throttle Free Play (Std.) 0.010- o.OJO" (.25-.76rnm)
Tool must extend to front
edge of slide
'
MIKUNI
i
0
EZ Throttle 0.050- 0.060" (1.25-1.50mm)
9/97
~orward
5.39c
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Adjustments • Choke
Choke Adjustments
With the dash mounted choke control toggle flipped to the
fu ll off position , the choke plunger must be seated on the
fuel passage way in the carburetor. If the plunger is not
seated on the passage way, the engine will flood or run too
rich, causing plug fouling and very poor engine performance.
Choke Toggle Position
If cable slack is too great there will be excessive toggle free
play resulting in hard cold starting. Also, the half on position
used for intermittent applications will not function.
If the choke lever assembly becomes damaged, a lever kit
is available. This allows replacement of the lever assembly
rather than the entire cable assembly. Installation instructions are included with the kit.
... ·cn.~ke Lever tOts..
Full On
·
f.m:a-'(
Contents of Lever Kit
Adjustment Procedure
1. Flip choke toggle to full off position.
2. Loosen adjustment locknut (A) on carburetor(s).
3.
Turn cable sleeve adjusting nut (B) clockwise on
carburetor(s) until 1/4" (.6 em) or more choke toggle
free play is evident.
4. Turn cable sleeve adjusting nut counterclockwise on
one carburetor until toggle has zero free play, then
rotate it clockwise until1/8"-1 /4" (.3-.6 em) toggle free
play is evident.
5. Tighten adjustment locknut (A) .
6.
Repeat steps 4 and 5 for remaining carburetor(s) .
1/8-1 /4" (.3-.6 em)
Freeplay
11/95
5.40
Polaris Industries Inc.
FUEL SYSTEMICARBURETION
Adjustments
The amount of air drawn into the cylinders is influenced by such factors as altitude, temperature,
humidity, etc. Suppose the amount of air drawn into
the cylinders at an elevation of zero is taken as 100
(the temperature and humidity in this case are considered constant). The amount of air in question decreases in proportion to a rise in elevation as shown
in Chart A. Reduction in the amount of air drawn into
the cylinders changes the air/fuel mixture ratio, resulting in a marked drop in power output.
Chart A
100
r
90 80 -
I
I
0
500
I
1000
I
1500
2000
Altitude (m)
Chart 8 shows the relationship between a rise in
temperature and the amount of air drawn Into the
cylinders. In this case, the atmospheric pressure
(elevation) and the humidity are considered unchanged and the amount of air going into the cylinders at 32° F (0° C) is taken as 100.
Chart 8
100
r
90
f-
80
~
-----------I
I
0
10
32
50
I
I
20
30
68
86
Temperature
On Mikuni VM carburetors the pilot system and the
main system are of independent construction. The
fuel flow in these two systems is shown in Chart C.
Total amount of fuel
Main fuel system
Pilot fuel system
Throttle valve ooenlng (%) ...,
CHART C
Polaris Industries Inc.
5.41
11/95
FUEL SYSTEM/CARBURETION
Fuel Pump - Operation
The fuel pumps on all Polaris engines are basically the same.
The differences are in the size and location of the pumps.
Pumps may be mounted to the engine or to the chassis.
In the two cycle engine, the pressure in the crankcase changes
with the up and down stroke of the piston. The amplitudes of
pressure vary according to the RPM and degree of throttle
opening. Whether idling or at full throttle, the pressure built up
in the crankcase has enough amplitude to operate the pump.
When the piston is on the upstroke, crankcase pressure in that
cylinder becomes less positive. The diaphragm in the fuel pump
moves toward the engine, causing a negative pressure or suction in the pump chamber. This causes the inlet valve from the
fuel supply to open and permits fuel to enter the chamber. This
same suction causes the outlet valve (to the carburetor) to close
so that fuel cannot return form the carburetor.
When the piston begins its downward stroke, the pressure from
the crankcase becomes positive, causing the fuel pump diaphragm to move in the opposite direction and reversing the
pressure in the fuel pump chamber. This causes the inlet valve
in the pump to close and the outlet valve to open, filling the float
bowl in the carburetor. When the float level in the carburetor
reaches its standard level, the needle valve will close, preventing more fuel from entering the carburetor, even though the fuel
pump continues to try to provide the carburetor with fuel.
Maintenance
The impulse operated diaphragm fuel pump does not require any specific scheduled maintenance. However, the
following procedures should be observed.
Operation:
•
The pump may be checked for operation by removing the fuel supply line from the carburetor
and placing it into a container. With the engine
idling at approximately 2000 RPM, a steady flow
of fuel should be visible.
Cleaning:
•
The pump and impulse line must be disassembled and cleaned of foreign material in the
event of piston or other internal engine part failures which produce fragments.
Inspection:
11/95
•
Disconnect impulse line from pump. Connect
Mity VacrMto impulse fitting (or line) and apply
4-6 PSI pressure. Diaphragm should hold pressure indefinitely.
•
The diaphragms and check valves must be carefully examined for cracks, holes, or other damage. If in doubt as to the condition of any internal
parts, replace all diaphragms, check valves, and
gaskets.
5.42
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Exploded View Fuel Pump
Taio Giken
Description of Parts
1. Vacuum (from crankcase)
2. Diaphragm
3. Gaskets
4. Check Valves
5. Fuel Outlets (to carbs)
6. Fuel Inlet (from tank)
Polaris Industries Inc.
5.43
11/95
FUEL SYSTEM/CARBURETION
Exploded View - Twin Cylinder (Typical) Fuel Pump
3
2~------.1
Parts Description
1. Pump Body Assembly
2 . Lower Gasket
3. Diaphragm
4. Upper Gasket
5 . Screw (6 used)
6. Check Valve
11/95
5.44
Polaris Industries Inc.
FUEL SYSTEM/CARBURETION
Exploded View- 3 Cylinder Fuel Pump
Parts Description
1. Pump Valve Body
2. Diaphragms and Gaskets
3. Screw (6 used)
4. Check Valves
NOTE: Be sure of proper order and
position of gaskets and diaphragms
upon reassembly.
5. Fuel Outlet (3 to carbs)
6. Fuel Inlet (from tank)
7. Vacuum/Pressure (from crankcase)
2
7-------4~
Polaris Industries Inc.
5.45
11/95
FUEL SYSTEM/CARBURETION
Water Trap Service
A
WARNING
Fuel spillage will occur during this installation. Gasoline is extremely flammable and explosive under certain
conditions.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where
~ gasoline is stored.
'f
'f
-.__/
Do not weld or operate a torch near the fuel system. Remove fuel tank before any chassis welding is per-
~ formed.
A
A
'f
If you get gasoline in your eyes or if you swallow gasoline, see your doctor Immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poison-
~ ous and can cause loss of consciousness and death in a short time.
1. Turn fuel valve off.
2.
Remove air silencer.
3.
Position a shop cloth or container below drain
plug and water trap plug.
4.
Remove drain plug and sealing 0-Ring, or slide
clamp upward and remove water trap plug.
5.
Drain water/fuel.
Clean trap with electrical
contact cleaner and dry with compressed air.
6. Lightly grease 0-ring and install water trap
assembly into bottom of float bowl, or reinstall
trap plug in hose and position. Tighten securely.
Float
Bowl
- - - 0-Ring
Drain
Plug~
7. Turn fuel on, start engine and check for possible
fuel leaks.
8.
Reinstall air box.
Clamp
The water traps should be periodically inspected and
drained. Draining frequency will depend upon fuel
supply, riding conditions, and fuel handling precautions.
I
~aterTrap
Plug
11/95
5.46
Polaris lndustnes Inc.
....__,/
FUEL SYSTEM/CARBURETION
Troubleshooting
Fuel system diagnosis should follow a specific path, first examining the fuel tank, then the filters, fuel lines, vent
lines , fuel pump, impulse hose, air box, exhaust system and finally the carburetors.
The following troubleshooting information assumes that the general mechanical condition of the engine (pistons,
rings, bearings, etc.} is good.
When the fuel/air mixture is diagnosed as improper due to spark plug readings, clean the carburetor and blow
its passages clear with compressed air. Use the spark plug firing end condition as a guide for further determination
of whether the mixture is too rich or too lean.
Use the throttle lever to determine at what degree of throttle valve opening the problem exists.
CONDITION
SYMPTOMS
Mixture Too Rich
-Black spark plug tip; plug fouling
-Heavy exhaust smoke
-Engine runs worse after warm up
-Engine "loads up"
Mixture Too Lean
-Spark plug electrodes white
-Fluctuation in engine speed
-Power loss
-Engine overheats
-Cylinder scoring I Holing pistons
-Backfiring- detonation
-Throttle diagnostic opening check points
Poor Fuel Mileage
-Incorrect ignition timing
-Improper track tension (too tight)
-Incorrect carburetor jetting
-Fuel leaks {lines, fittings, fuel pump)
-Needle and seat leaks
-Plugged exhaust
-Carburetor vent line problems
-Clutching incorrect for conditions I worn belt
Troubleshooting Tips, 0·1/4 Throttle:
•
Pilot air screw misadjusted
•
Pilot jet of wrong size, loose, or obstructed
•
Obstruction of pilot jet
•
Incorrect throttle synchronization
•
Choke plunger not seating (rich)
•
Carburetor mounting air leak (lean}
•
•
Crankshaft seal air leak (lean)
Fuel pump diaphragm damaged (rich)
•
Float level incorrect
•
Air bleed obstructed
Polaris Industries Inc.
5.47
9/96
FUEL SYSTEM/CARBURETION
Troubleshooting
Troubleshooting Tips, 1/4-3/8 Throttle:
•
Obstruction in main jet or needle jet
•
Jet needle worn or out of adjustment
•
Pilot system malfunction
•
Incorrect throttle valve cutaway
•
Incorrect throttle synchronization
Troubleshooting Tips, 3/8-3/4 Throttle:
•
Main jet incorrect size or clogged (lean)
Needle jet damaged or loose
•
Needle jet/jet needle worn (rich)
Incorrect throttle synchronization
Troubleshooting Tips, Full Throttle:
9/96
•
Main jet size (rich or lean)
•
Fuel filter blocked (lean)
•
Fuel vent lines or check valves plugged
•
Exhaust system plugged
•
Air box restricted
•
Fuel pump weak
•
Exhaust leaking into engine compartment (rich)
•
Water in float bowl (lean)
•
Incorrect throttle synchronization
5.48
Polaris Industries Inc.
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