
700 Polaris 2002-03 Exhaust System Installation
Remove entire stock exhaust system. Remove stock muffler mounting bracket. Remove stock exhaust manifold. Using stock manifold bolts and gaskets, install exhaust flanges onto cylinders. Drill a 1/4" hole in belly pan an 1 ½" in front of exhaust outlet hole. Using a 1/4" bolt and lock nut secure spring clip (provided in kit) in place. Stretch spring between floor and mufflers. (It will be easier before pipes are in position) Place aluminum shield over shock tower. Bend to fit and securely rivet into place. Place a bead of high-temperature silicone around exhaust manifolds to prevent leakage. Also place a bead around stingers where pipes and mufflers join. Place pipes into position beginning with the magneto pipe making sure that the flanges slide all the way together both at the manifold and the mufflers. Then install PTO pipe. Using stock springs, spring joints together. Make sure the oil injection cable is not touching pipes.
Recommended Clutching and Jetting Instructions
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MODEL |
0-4,000 ft Elevation |
4-6,000 ft Elevation |
6-8,000 ft Elevation |
8-10,000 ft Elevation |
| 02 700 Pol | ||||
| 03 700 Pol |
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