My sled was 100% stock. Last year, we made a last minute decision to ride in Wyoming and I had a dealer out there rejet it for me. Cost was around $75 and time was limited, so I didn't bother looking into doing it myself. This year, I'm finally getting around to jetting it back to stock and looking for advice before I take care of it. The sled has always been thirsty, so I was thinking it's worth trying to jet it a little different. I've thought about the ATAAC kit also, but jets are cheap.
Polaris Fusion 600 - changing jets and reinstalling airbox
- Thread starter Hoosier
- Start date
My sled was 100% stock. Last year, we made a last minute decision to ride in Wyoming and I had a dealer out there rejet it for me. Cost was around $75 and time was limited, so I didn't bother looking into doing it myself. This year, I'm finally getting around to jetting it back to stock and looking for advice before I take care of it. The sled has always been thirsty, so I was thinking it's worth trying to jet it a little different. I've thought about the ATAAC kit also, but jets are cheap.
indy_500
Well-known member
WHIMP! LOL me and my dad went up last year same weekend as this past one and rode it was -25 and no that was not the wind chill. Woke up the next morning and my dad bought a heated shield LOL
trailshredder
Member
Where was the temp at -25 last year. I don't remember anything that cold last year.
indy_500
Well-known member
Mercer WI Jan 18 Low Temp -22 Jan 19 Low Temp -23 just looked it up http://weathersource.com/account/of...-id=21178&latitude=46.1892&longitude=-90.0767 we unloaded late at night Thursday and tried going for a ride at around 9 pm. I have that same Friday off school every year.
trailshredder
Member
Yup....that's cold.
chiefcheese
Member
I was in Eagle River that weekend last year and rode my Fuze 600 without issue. Gutted airbox, 400 mains, .9 air pilots and I believe don't recall the pilot.... larger I think. The tricky part is adjusting the fuel screw. I still have a burble at low rpm but it cleans out quick as soon as it gets off the idle circuit. As long as your in Wisco/UP and are not below zero and pinning it for 3 miles over a lake I would not worry. I never had a DET light yet.
Check this out from Hardcore Sledder: http://www.hardcoresledder.com/forums/446-fusion/506284-600-ho-stumble.html
Interesting reading, even if you have done something different and do not agree. The dealer that I got my sled from told me that every brand new Polaris 2006 600 Fusion(over 15 that he sold) had upgrades, as follows, before they left his service department at no charge (.9 PAJ's, 50 Pilot Jets, and turn air screw out approx 1 turn + or -). Guess this dealer was covering a Polaris "F" up before it got out. Wish more dealers would do this type of thing, no matter what brand of sled, when they know that the manufacturer screwed up.
Lots of good input on here and on the HCS link... I need to pull the trigger tomorrow and order some parts. I am thinking the 410's for sure and probably the slp kit, both for air flow and for ease of reassembly. I don't understand the other jets and settings as much. Is it important to change those also or is stock close enough on those? The specific parts and setting came from calling js powersports, who seem to have a good reputation on HCS. I don't know if it's a good idea to change a lot of settings at once.
At some point I'm wondering if I'd just be better off buying the ATAAC kit and perhaps the SLP kit, and being done with it...
At some point I'm wondering if I'd just be better off buying the ATAAC kit and perhaps the SLP kit, and being done with it...
Overall gas mileage is poor. Also, it definitely doesn't seem to be as responsive to the throttle as it should be or compared to other Polaris' in the group, both Edge 600's and CFI 600's....I know there are other factors involved in both of these, but since I have to rejet anyway, I would like to nail down the jetting if possible. I'm tempted to just gut the box as Ezra said and call it a day.
Got the jobs done last weekend. Went with the recommendation from JS Powersports and bought the jets from them - 410 main, 0.9 PAJ, 35 pilot, needle #3. On my Fusion, the fuel screw was out about 2.5 turns, so I set it at 1.5 turns. On my bud's 07 600, it was at 1.25 turns, so we left it there. Nathan from JS Powersports said start with just over 1 turn.
We also bought and installed the SLP air horn kit. That was much more time-consuming than rejetting, although we didn't re-install the air box as we wanted to let the permatex dry before we messed with it too much.
Won't be able to ride it until President's day weekend. Hopefully all the jets work well. I haven't messed with carbs before, but it wasn't too difficult. I'm more concerned about changing all the settings at once...
We also bought and installed the SLP air horn kit. That was much more time-consuming than rejetting, although we didn't re-install the air box as we wanted to let the permatex dry before we messed with it too much.
Won't be able to ride it until President's day weekend. Hopefully all the jets work well. I haven't messed with carbs before, but it wasn't too difficult. I'm more concerned about changing all the settings at once...
I have a 07 IQ that I run 400's for mains and have gone down to 390's with no problems. I have a ETG and have found that the 600 HO runs very lean in the mid-range not on top. Also the pilots are too lean and the air jet too rich. As far as the air box, it takes about 15 min to install, spray some lube on the boots make sure that the cables behind the air box are out of the way and then push the box down and then tilt the bottom up and it will slide on the carbs.
I have read other posts that these sleds are too lean on the midrange also...doesn't moving the needle down to the 3rd position compensate for that?
What do you mean that the pilots are too lean and the air jet is too rich? I thought it was the opposite, which is why it seems most increase the size of the pilot air jet and reduce the size of the pilot jet??
I'm a little new at this, but my understanding is that the main jet impacts mostly above 1/2 throttle, the needle and needle position impact 1/2 throttle, and the pilot jet, pilot air jet and fuel screw impact idle.
I can double check this weekend when I get up to my cabin. I know the setting seems odd but I have run this jetting since the sled was new in 07 and have nearly 8000 miles. The air jet controls the idle and the sled will load up at idle. Then it has a bog off of idle and the pilots control off idle. You are correct the by dropping the clip one groove that will make the mid range richer. The sled will respond better but you gas mileage will suffer. The lean condition in mid range is more of a problem when the pipe was cold and if you held the throttle steady in the mid-range. I will double check this weekend for the jetting on my sled and reply back on Monday
I am probably over-thinking this, but we installed the 35 pilot jets along with the 0.9 PAJ's...is there any harm in running a pilot jet that small? That was what was recommended to me, but from reading the message boards it seems way more common to run 40's or 45's. If this is too lean, will it just idle too high or can this cause bigger problems? If it just idles too high, can this be fixed by opening the fuel screw a little further? Again, I'm probably over-thinking this, but this is my first time through snowmobile carbs and I can't really test it till we get them north and I want to be ready if it doesn't run right....thanks
chiefcheese
Member
Pilots
I looked up my setup and I used .60 pilots. .9 air and 400 mains. This was the setup I have run without issues for a while now. Ran to10 below or more. Just have to fiddle with the fuel screw a bit. If you have a hesitation just off throttle try the choke at the first position. If that helps off throttle it is too lean. Turn out the fuel screws a 1/8 or 1/4 turn and try again. If you have a bog that gets worse with the choke its a bit rich off idle so turn back in. I know I tconfirmed this with Willie over at HCS via email...he ran this in many Fusions in Quebec where his shop is. I also have a n article from 2006 from a race guy that tested and perfected it to the same setup. Hope it helps but i can tell you it's worth it. Key: check piston wash and plug color. That will show you the way. Also..if you have not replaced the carb boots do it when you pull the carb rack. Original ones are junk. -chiefcheese
I looked up my setup and I used .60 pilots. .9 air and 400 mains. This was the setup I have run without issues for a while now. Ran to10 below or more. Just have to fiddle with the fuel screw a bit. If you have a hesitation just off throttle try the choke at the first position. If that helps off throttle it is too lean. Turn out the fuel screws a 1/8 or 1/4 turn and try again. If you have a bog that gets worse with the choke its a bit rich off idle so turn back in. I know I tconfirmed this with Willie over at HCS via email...he ran this in many Fusions in Quebec where his shop is. I also have a n article from 2006 from a race guy that tested and perfected it to the same setup. Hope it helps but i can tell you it's worth it. Key: check piston wash and plug color. That will show you the way. Also..if you have not replaced the carb boots do it when you pull the carb rack. Original ones are junk. -chiefcheese