800 Polaris 2000-01 Exhaust System Installation

 

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

    NOTE:  Do not advance the timing on the '01 sled.

 

 

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

00 800 Pol

330 & 350 main jets, run key setting on regular, use 10-64 gram weights

320 & 340 main jets, run key setting on premium, may need to lighten weights 1 gram

310 & 330 main jets, run key setting on premium, use 10-62 gram weights

01 800 Pol

400 main jets, run key setting on regular, use 10-64 g weights, raise needle one position, richen fuel screw ½ turn

380 main jets, run key setting on premium, may need to lighten weights 1 gram, raise needle one position, richen fuel screw ½ turn

360 main jets, run key setting on premium, use 10-62 gram weights, raise needle one position, richen fuel screw 1/4 turn