
800 Skidoo 01-03 Exhaust System Installation
Remove entire stock exhaust system and exhaust manifold. Drill a 1/4" hole in belly pan and 1 1/2" 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. (Its will be easier before pipes are in position.) *For '02 sleds only: The exhaust outlet will have to be moved on the 02 sleds; install pipes, slip mufflers into place, mark and use a hole saw to cut new outlet hole. If desired, the '01 aluminum plate fits the '02 machine and the muffler will exit. Using a heat gun, heat belly pan until soft. Then install mag pipe and sit on it, making a valley on top of the shock tower. 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. Remove right center vent. Trim rib between two vents until there is a gap. Gut the airbox. Move the clicker to 1 or 2. Needs to run at 8000 RPM.
Recommended Clutching and Jetting Instructions:
0-4,000 ft elevation 4-6,000' elevation 6-8,000' elevation 8-10,000' elevation 01 800 Skidoo 720 Main jets 680 main jets & washers under the needles, add 1 gram weights 660 main jets & washers under needles 660 main jets & washers under the needles 02 800 Skidoo 720 Main jets Stock needle position 680 main jets 660 main jets 03 800 Skidoo Jet up 3 or 4 sizes, and leave airbox Jet up 3 or 4 sizes, and leave airbox Jet up 3 or 4 sizes, and leave airbox Jet up 3 or 4 sizes, and leave airbox