2003 800 XCSP I know bad year. Anyway I was up North this past week. Everything was great. Till Sat. we were riding on Trails all day and we went back across the lake when I noticed I could only go about 90mph and only had 7800RPMs. I had just raced that morning and I know I had over 8000rpms and over 100mph. I beat everyone I was with. Now they stay with me. sled is all stock. It has the updated CDI box. Crank was replaced about 1000 miles ago. I had this same problem before and It was a broken exhaust valve. It is not the problem this time. I took them apart and all is fine. It has a new belt & new plugs. Sled has about 2100 miles on it. The sled still pulls hard and runs fine just low RPMS. Any help would be great. I am going North again in 2 weeks I hope with this sled. When the crank went last time It would not go over 40mph.and made a hell of a clunking noise.like i said no noise and seems no different at low RPMS. I know the crank is a know problem in this sled. I hope it is not that again. Please Help! Thanks Travis

Anyone

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Give your clutches a good over. Make sure a spring is not broken or something is binding.

Ok, I'll start with the basics. Was there anything different about the riding conditions during the week and when it started running a lower RPM? (Did the temps go up outside, big barometric pressure change, snow conditions change hardpack to slushy)

Just asking, cuz I've had sleds that would run crisp in the morning and then lose a couple hundred rpm's as the temps went up during the day, especially with sleds that were clutched on the edge. Example 700 Polaris twin pull 66g weights. Under the right conditions it's fine but otherwise, it can't handle the weight and you lose some r's

Check for a flat spot in primary clutch rollers or looseness in weights. If they are loose they'll catch on the side of clutch and not close the clutch properly.

Good luck

my guess is that your secondary spring is worn out. i had my epi spring fail on me just like that. runs fine then......runs like shit and cant pull proper rpm without any warning. my .02

good luck

Does your "03" have a premium switch on the key? When I switch my 02 700 from premium to regular, I loose 200 rpm's.

You say you looked at the exhaust valves. Did you take them apart to look at the bellows. My '03 700 did the EXACT same thing to me. Going great and then all of a sudden a drop in RPM and performance. I had a tear in the one bellow and a pinhole in the other. Polaris updated the bellows for these sleds. They are now a more durable material and are now orange. Replaced mine and she is rockin' once again. Take a look and post back.

FYI, max HP is @ 7,800 RPM on the 800 twin. Is your tach calibrated? What jetting you have in it?
Is the air box boot all the way on the mag side carb?
Check to make sure ves bellows is tight on the valve. I've machined the aluminum nut to get it to tighten down farther, to hold better without loosing pressure, on a few sleds that the bellows was loose enough to spin on the valve, even with the nut tight.

the weather was the same. Valves are fine I havs ss with the new bellows. I think I am going toward the clutch. If I have them gone threw should I change the weights and spring from stock?? If so what should I put in it. I mainly Trail ride. Anyhelp would be great Thanks.

Now the dam sled only pulls 7500 RPM I give up. I think it is going to the shop.

my sled does the same thing, I can't figure it out.

Check the clutch springs both primary and secondary. Start from there, they are around $40 for both. You should change your springs every couple years because they loose tension.

well sled is know at the shop. I will let you know what they find in about a week they said.