800 Polaris - 2002-04 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 1/2" 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 strap (side with hole) on shock tower. Drill hole in shock tower and rivet into place.
  7. Then, drill hole in other end of strap and belly pan, then secure it with a rivet and washer.
  8. Place a bead of high-temperature silicone around exhaust manifolds to prevent leakage. Also place a bead around stingers where pipes and mufflers join.
  9. 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.
  10. Using stock springs, spring joints together.
  11. Gut air box.
  12. Shorten radiator hose so that it won't touch the PTO pipe. Re-secure hose with hose clamp, and refill antifreeze. (Do not pull too far toward head so that rewind cord rubs hose at bulkhead. You may have to shorten a little on brake end.)


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
02 800 Pol

& 03 800 Pol 04 800 Pol

 jet up 4 sizes from stock jets, use 10-66 gram weights, leave timing stock

 

 

 

 

 

 

 400 & 410 main jets, run key setting on regular, use 10-64 gram weights  

 360 & 370 main jets, run key setting on premium, use 10-64 gram weights, use blue/white exhaust valve springs, recommend R4 driven clutch cam 50-32.  

 360 & 350 main jets, run key setting on premium, use 10-64 gram weights, use blue/white exhaust valve springs, recommend R4 driven clutch cam 50-32. On '04 sleds - Use 360 & 350 main jets, run key setting on premium, use 10-64 gram weights, and use red/black spring on driven.