700 Polaris 1997-2001 Exhaust System Installation
  1. Remove entire stock exhaust system.
  2. Remove stock muffler mounting bracket.
  3. Remove stock exhaust manifold.
  4. Using stock manifold bolts and gaskets, install exhaust flanges onto cylinders.
  5. Drill a 1/4" hole in belly pan an 1 ½" in front of exhaust outlet hole.
  6. Using a 1/4" bolt and lock nut secure spring clip (provided in kit) in place.
  7. Stretch spring between floor and mufflers. (It will be easier before pipes are in position)
  8. Place aluminum shield over shock tower. Bend to fit and securely rivet into place.
  9. Place a bead of high-temperature silicone around exhaust manifolds to prevent leakage. Also place a bead around stingers where pipes and mufflers join.
  10. 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.
  11. Using stock springs, spring joints together. Make sure the oil injection cable is not touching pipes.

For 97-98 Only

It will be necessary to trim vent screens and aluminum cross brace on the hood. Move cable mounting screw so it clears pipe.

For 99-00 Only

Remove high altitude compensator. Remove aluminum reflector shield on the hood.

 


Recommended Clutching and Jetting Instructions

MODEL

0-4,000 ft Elevation

4-6,000 ft Elevation

6-8,000 ft Elevation

8-10,000 ft Elevation

700 Polaris
1997-2000

 175 & 178 main jets, use 10-64 gram weights

168 & 170 main jets, use 10-62 gram weights

165 & 168 main jets, use 10-60 gram weights

162 & 165 main jets, use 10-60 gram weights

700 Polaris
2001

 Raise jets 4 sizes from what currently using

Raise jets 4 sizes from what currently using

Raise jets 4 sizes from what currently using

Raise jets 4 sizes from what currently using