Polaris Fusion 600 - changing jets and reinstalling airbox

[Hoosier]

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

THanks. I'll keep these tips in mind when we get the sleds out in a couple weeks. We did check the carb boots when we had it apart. The ones on my Fusion have been replaced once before. The ones on the 07 are stock.

 

[Hoosier]

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

Thanks. Let me know what you find out. I probably wouldn't be as concerned if my bud didn't jet his 07 600 the same, based on what I figured out.

I did look up a service manual for the 08 Shift, and stock jetting for that is: 400 mains, needle #3, paj 1.0, pilot 45. So, I think I'm very close to all those I think (mine is 410/#3,0.9,35, + air horn kit), other than whatever changes the air horn kit causes. I'll probably just have to be careful if it is extremely cold or if I have to run lower octane. My understanding is that the total gas at higher throttle positions is the combined amount from the main and the pilot. So if a lot of guys are running 45 pilots with 400 mains, it should be similar to running 35 pilots with 410 mains. Plus the needle at 3 should fatten it some also.

 

[Hoosier]

Finally had a chance to run both rejetted sleds today. Both ran great but both idled at 3500. Is the best solution the simple one -adjust the idle screw on top of the carbs, or is it more likely something isnt right with the jetting? Plan to adjust tomorrow before riding..

 

[fastmod62]

You can try to adjust the idle screw, if that doesnt work try flipping the choke lever to half way for a second. Does the idle drop if you flip the choke a little? If it does you need to open the idle air screws another turn. Or go to a bigger pilot jet. I run 410 main's 55 pilots needle in #2 slot with a .9 PAJ 1.5 turns on the air screws and have no stumble @ all, gonna drop to 400 mains next time I have the carbs off.