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  1. #1
    ph2ocraft's Avatar
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    Misc Technical Up-dates

    I'm going to start adding technical up-dates here. They will be in no particular order. Some are service team tips and up-dates that you might find apply to your ride. If nothing else it's kind of neat to see the changes and/or corrections made as the years went on.

    Correct torque for the 700 twins (it was wrong in some manuals)
    Cylinder base nuts 35-40 ft pounds.
    Cylinder Head Torque 20 ft pounds.


  2. #2
    ph2ocraft's Avatar
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    Removing a Flywheel

    DONT'S
    Never strike a flywheel
    This may break or crack the magnets.

    Don't use air tools
    This may break or crack magnets and of course ruin your puller tool.

    Don't apply heat
    Heat may loosen the bonding of the magnets or reduce their strength. You may also damage the stator or ruin seals.

    DO'S
    Use a high quality puller with a large center bolt so adequate torque can be applied to pull the flywheel.
    Use a bar or wrench to prevent the puller from turning. If the puller body turns the small hub bolts may may bend or flex, causing misalignment.
    Install puller bolts evenly. This ensures even tension and maximizes pressure for removal. Make sure the washers provide good support without flexing or bending. Use the shortest bolts possible for minimum "stretch".
    Careful of the stator. Screw the bolts in far enough only to engage all available threads in the flywheel hub, any more and you could damage the stator.
    Inspect Taper of the Crankshaft. Be sure it's clean and dry and use loctite 262 where instructed.
    Woodruff key, make sure it fits tightly into the crankshaft keyway.
    Retaining Nut, be sure to apply Loctite 242 and torque to specification.
    Apply grease to puller. Grease to the puller threads and tip will make removal easier and extend the life of your puller.

  3. #3
    ph2ocraft's Avatar
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    1050 Domestic Hesitation

    The hesitation or bog can usually be corrected with a 1/8 turn out of the low speed screws. Most are 7/8 turns out and a setting of 1 turn will usually do the trick. Make sure the idle speed is set at 1200-1300RPM's in the water.

  4. #4
    ph2ocraft's Avatar
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    1/4 AMP Fuse Polaris Part Number

    Most of us just get our 1/4 amp fuses for the MFD's from Radio Shack but they are available from your Polaris dealer.
    Part number is 4060111

  5. #5
    ph2ocraft's Avatar
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    Muffler Support Bracket

    The 96/97 SL900, SL1050 and SLTX have a muffler (water box) that will slide backward and possibly wear hoses and wear the box. The bracket and bumper numbers are 5410414 (bumper) 5242465 (bracket) and prevent the water box from sliding backward. The bracket attaches to the top left pump mounting stud and prevents the muffler and hoses from moving rearward.

  6. #6
    ph2ocraft's Avatar
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    Hard Start/High Speed Misfire

    All the older style PVL systems on the 700, 900 and 1050 will benefit from this little tip.
    Change the gap down to .020. Be sure to use a wire gauge and not a feeler gauge as the feeler gauge will usually leave a gap wider than that you are trying to achieve. Be sure you're using resistor type plugs!!

  7. #7
    ph2ocraft's Avatar
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    700 single carb kit

    You can convert your twin carbureted set up to a single carb set up.
    The kit (if still available) is 2871857 and includes a pre-jetted carb, manifold, air filter and gaskets.

  8. #8
    ph2ocraft's Avatar
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    Sponson Insert Kit

    Kit number is 2871555
    Insert Tool Only is 2871469
    The kit contains the insert tool, inserts and adapters.
    10-32UNC; 1/4-20; 5/16-18

  9. #9
    SPEED KILLS, BUT YOU GET THERE QUICKER Keddano's Avatar
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    Nice job,Keep picking the brain...... The meds are finally totally getting out of the system.(For those that didn't know,AL had a new hip put in a while back) Now think back to the old race days. What was some of the hot race and speed tricks.

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