Tech Tips

Most all of these tech tips or tech articles I stoll, so I just see this as a central portal to super tuning your Polaris.
Tip #1 buy a Polaris,  Ski Doo =   slow (Live it - Learn it...)

Choose your Topic:
The Holeshot
Pilot Air Screws
Gearing your sled
TPS Adjustment

Carb Boot Mod
Establishing a Jetting Baseline
Airbox Temperatures
Pipe Temp and Airbox Pumping
Torque or Horsepower?
INSIDE Suspension Coupling!
CHOOSING AN OIL!
NGK Spark Plugs


 
The Holeshot (Just for Buzz)
Getting off the starting line is crucial to winning in many forms of racing, from drag racing your buddies to sno-cross.  There are some basics that can help.  Traction, suspension, clutching and gear ratios will be the focus of this article.  Of course it is also important to have a torque-filled powerful engine, but we are going to concentrate on tuning the sled to utilize the power you already have.

The way you obtain good traction for your holeshot is dependent on the surface on which you are riding.  For snow, deep lugs are needed.  Ice requires sharp studs.  If the ice is soft, a few chisel studs may help.  Chisels also work for dirt or grass.  The following recommendations are made under the assumption that traction has already been maximized.

Weight transfer is a critical factor.  Because the center of gravity of a snowmobile is above the line of force, the point where the track grips the snow, ice or ground, the front of the machine rises upward when you accelerate.  The rear suspension should be set to capitalize on this principle of physics.  Two things should happen: The rear springs should compress and the center spring, front of the rear suspension, should extend.  The result should be a transfer of weight to the rear of the sled which pushes down on the track.  If the front end of the sled comes up too high a couple of bad things happen.  First, you have wasted energy by going up with the front of the machine instead of forward.  Secondly, the front portion of the track will not grip the surface well.  On the other hand,  if the front end does not come up at all, then weight has not been transferred.  This means that the skis are dragging and the track does not grip as well because there isn't as much weight on it.  If the rear suspension is set correctly, the skis should come up a few inches and the track should be flat on the riding surface.

This is accomplished by extending the limiter straps, increasing the preload of the spring of the front of the rear suspension and softening the rear springs.  There is no free lunch here, however.  These adjustments have a negative effect on your sled's ability to corner.  The inside ski will lift more readily.  If you are out drag racing with your buddies, soften the rear springs (softest cam setting or lighter springs) and let out the limiter straps enough so the skis come off the surface a few inches.  Now set the preload on the center spring, front of rear suspension, very stiff.  This will give the track good bite.  On the other hand, if you are riding the twisties through the woods, start sucking up the limiter straps until your sled corners to your liking.  A middle ground setting would be to keep the rear springs fairly soft, shorten the limiters until you can live with the corners and keep a high preload on the center spring.

Let's take a look at clutching.  The objective for clutching a snowmobile for a good hole shot is to utilize as much of the engine's available torque as possible without spinning the track.  Once the track breaks loose, traction is lost.  There is a lesson to be learned from driving a car on ice.  To get started it is beneficial to start out in second gear.  When we do this we have limited the engine's torque to match the available traction.  This is also true for snowmobiles.  Most sleds have ample torque to spin the track on take off on almost any surface.  We need to limit it, especially just as the sled begins to move.  This can be done in a number of ways.  The easiest is to adjust your drive belt lower in the secondary, which is like starting out in second gear.  Torque is force times distance, and putting the belt closer to the jackshaft reduces the distance, thereby reducing the torque.  This also means the primary clutch will slip more before it grabs the belt.  Belts won't last as long.

Another method is to install a different helix that will allow the clutches to shift to a higher ratio very rapidly at the beginning of the launch, but then slow down the upshift shortly thereafter.  This is done with a multi-angle helix.  A rule of thumb here is to have the first number about ten more than the stock straight-angle helix and the second number about two less.  Fine tuning can be done with the belt position and spring tension in the secondary.  For example, if the engine bogs, the belt can be raised in the secondary and/or the spring tension can be increased.  On the other hand, if the track still spins too readily, the belt can be lowered in the secondary.  You probably don't want to reduce spring tension because that will affect your backshift.  If the shift-out R.P.M. are changed this should be adjusted with changes in the primary clutch.  It can be done by changing springs: lighter to lower R.P.M. or heavier to raise them.  You can also add or subtract weight to the lever arms or fly weights.

Changing sprockets can also be considered.  A larger top sprocket will reduce torque.  This change will effect the entire pattern from low end to top end.  It will help limit track spin but probably will also reduce acceleration.  It may, however, increase top end.  Speed-run people like big-top sprockets.

These are some basics for tuning for a good holeshot.  Hopefully, they will be helpful as you attempt to fine tune your sled to meet your riding needs.  Good luck.


Pilot air screws

Many Polaris XC's owners are frequently annoyed by a high idle.  Many dealers recommend turning out the fuel screws to richen the idle mixture, but that just loads up the engine.  A much better solution is to install 1.0 PAJs (Pilot Air Jets) in place of the 0.9s that come stock.  We found that the 1.0 PAJs helped DE-sensitize the carb idle circuits and made the "high-idle" problem much less bothersome.  And yes, I know that some guys went to smaller PAJs and screwed out the fuel screws in an effort to do the same thing... I don't consider flooding the engine with unneeded fuel a solution.  The 1.0 PAJs allow you to turn down the idle speed, and idle comfortably without loading up.  Replacing the PAJs is very easy to do and doesn't require taking apart the carbs.  Just open the top of the airbox and lay it aside.  You will see the carb throats, and the PAJs are right there.  Use a small screwdriver and DON'T DROP them in the engine!

The correct Polaris part number for the long 1.0 PAJs is 3131257.


Formula to calculate MPH:
RPM / GR x SC / 12 x 60 / 5280 = MPH @ 1:1 clutch ratio
GR = gear ratio (divide top sprocket into bottom sprocket)
SC = sprocket circumference

7T - 2.52" Pitch = 17.64 SC
8T - 2.52" Pitch = 20.16 SC
9T - 2.52" Pitch (std. OEM size) = 22.68 SC
10T - 2.52" Pitch = 25.2 SC
7T Convolute - 3.29" Pitch = 23.03 SC


Formula to calculate chain:
(CD x 2)/.375 +(TS + BS)/2 = Pitch
CD = center distance (drive shaft to Jackshaft)
TS = top sprocket
BS = bottom sprocket
--Round number up to even number for proper pitch


Gearing

600 & 800 gearing recomendation chart. The column at the far right has chain slack under the "Differ" heading.
Example: Stock 800 edge has 25 tooth upper 40 tooth bottom and 76 pitch chain = 1.60 ratio with .187 chain slack.
That chain slack is what makes all that brake noise. So going to a 24/39 gear set with a 74 pitch chain - 1.63 ratio with .002 chain slack. Brake noise will be reduced and a straight chain equals better effenciancy. You will need to grind some material off the backside of the tensioner to fit.

For you 600XC boys go from stock 23/39 gears to 22/37 gears with a 72 pitch chain. 

Remember numerically lowering ratio will increase mph
Example
1.60 ratio at 8000 rpm=107.4 mph.
1.63 ratio at 8000 rpm=105.7 mph

SNOWMOBILE SPROCKET / CHAIN COMBINATIONS  (RED=no good, N/R=Not Recommended, BLUE=can be used safely)
XCF STANDARD CHAINCASE, 6.625 CENTER DISTANCE 7.050 CENTER DISTANCE CHAINCASE
(97 and later RMK, XC)
EDGE 7.920 CENTER DISTANCE CHAINCASE
UPPER
LOWER 
CHAIN
DIFFER
UPPER
LOWER 
CHAIN
DIFFER
UPPER
LOWER 
CHAIN
DIFFER
SPRKT
SPRKT
CHAIN
CNTR
CHAIN CD
SPRKT
SPRKT
CHAIN
CNTR
CHAIN CD
SPRKT
SPRKT
CHAIN
CTR
CHAIN CD
RATIO
# TEETH
# TEETH
PITCH
DIST
CASE CD
# TEETH
# TEETH
PITCH
DIST
CASE CD
# TEETH
# TEETH
PITCH
DIST
CASE CD
2.56
16
41
66
6.869 
0.244 
16
41
68
7.253 
0.203 
16
41
72
8.018 
0.098 
2.50
16
40
66
6.978 
0.353 
N/R
16
40
68
7.361 
0.311 
N/R
16
40
72
8.124 
0.204 
2.44
16
39
64
6.703 
0.078 
16
39
66
7.086 
0.036 
16
39
72
8.229 
0.309 
N/R
2.41
17
41
66
6.786 
0.161 
17
41
68
7.170 
0.120 
17
41
72
7.933 
0.013 
2.35
17
40
66
6.895 
0.270 
N/R
17
40
68
7.277 
0.227 
17
40
72
8.039 
0.119 
2.31
16
37
64
6.918 
0.293 
N/R
16
37
66
7.299 
0.249 
N/R
16
37
70
8.059 
0.139 
2.29
17
39
64
6.620 
-0.005 
N/R
17
39
68
7.383 
0.333 
N/R
17
39
72
8.144 
0.224 
2.28
18
41
66
6.703 
0.078 
18
41
68
7.086 
0.036 
18
41
74
8.229 
0.309 
N/R
2.22
18
40
66
6.811 
0.186 
18
40
68
7.193 
0.143 
18
40
72
7.954 
0.034 
2.19
16
35
62
6.749 
0.124 
16
35
64
7.129 
0.079 
16
35
70
8.266 
0.346 
N/R
2.18
17
37
64
6.833 
0.208 
17
37
66
7.214 
0.164 
17
37
70
7.973 
0.053 
2.17
18
39
66
6.918 
0.293 
N/R
18
39
68
7.299 
0.249 
N/R
18
39
72
8.059 
0.139 
2.16
19
41
66
6.620 
-0.005 
N/R
19
41
70
7.383 
0.333 
N/R
19
41
74
8.144 
0.224 
2.11
19
40
66
6.727 
0.102 
19
40
68
7.108 
0.058 
19
40
74
8.249 
0.329 
N/R
2.06
17
35
62
6.663 
0.038 
17
35
64
7.043 
-0.007 
N/R
17
35
70
8.180 
0.260 
N/R
2.06
18
37
64
6.749 
0.124 
18
37
66
7.129 
0.079 
18
37
72
8.266 
0.346 
N/R
2.05
19
39
66
6.833 
0.208 
19
39
68
7.214 
0.164 
19
39
72
7.973 
0.053 
2.05
20
41
68
6.918 
0.293 
N/R
20
41
70
7.299 
0.249 
N/R
20
41
74
8.059 
0.139 
2.00
20
40
66
6.643 
0.018 
20
40
70
7.404 
0.354 
N/R
20
40
74
8.163 
0.243 
1.95
21
41
68
6.833 
0.208 
21
41
70
7.214 
0.164 
21
41
74
7.973 
0.053 
1.95
20
39
66
6.749 
0.124 
20
39
68
7.129 
0.079 
20
39
74
8.266 
0.346 
N/R
1.95
19
37
64
6.663 
0.038 
19
37
66
7.043 
-0.007 
N/R
19
37
72
8.180 
0.260 
N/R
1.94
18
35
64
6.957 
0.332 
N/R
18
35
66
7.336 
0.286 
N/R
18
35
70
8.093 
0.173 
1.90
21
40
68
6.939 
0.314 
N/R
21
40
70
7.318 
0.268 
N/R
21
40
74
8.077 
0.157 
1.86
22
41
68
6.749 
0.124 
22
41
70
7.129 
0.079 
22
41
76
8.266 
0.346 
N/R
1.86
21
39
66
6.663 
0.038 
21
39
70
7.422 
0.372 
N/R
21
39
74
8.180 
0.260 
N/R
1.85
20
37
66
6.957 
0.332 
N/R
20
37
68
7.336 
0.286 
N/R
20
37
72
8.093 
0.173 
1.84
19
35
64
6.871 
0.246 
N/R
19
35
66
7.250 
0.200 
19
35
70
8.006 
0.086 
1.82
22
40
68
6.853 
0.228 
22
40
70
7.233 
0.183 
22
40
74
7.990 
0.070 
1.78
23
41
68
6.663 
0.038 
23
41
70
7.043 
-0.007 
N/R
23
41
76
8.180 
0.260 
1.77
22
39
68
6.957 
0.332 
N/R
22
39
70
7.336 
0.286 
N/R
22
39
74
8.093 
0.173 
1.76
21
37
66
6.871 
0.246 
N/R
21
37
68
7.250 
0.200 
21
37
72
8.006 
0.086 
1.75
20
35
64
6.785 
0.160 
20
35
66
7.163 
0.113 
20
35
70
7.918 
-0.002 
1.74
23
40
68
6.768 
0.143 
23
40
70
7.147 
0.097 
23
40
76
8.282 
0.362 
N/R
1.71
24
41
70
6.957 
0.332 
N/R
24
41
72
7.336 
0.286 
N/R
24
41
76
8.093 
0.173 
1.70
23
39
68
6.871 
0.246 
N/R
23
39
70
7.250 
0.200 
23
39
74
8.006 
0.086 
1.68
22
37
66
6.785 
0.160 
22
37
68
7.163 
0.113 
22
37
72
7.918 
-0.002 
1.67
21
35
64
6.698 
0.073 
21
35
66
7.076 
0.026 
21
35
72
8.207 
0.287 
N/R
1.67
24
40
68
6.682 
0.057 
24
40
70
7.060 
0.010 
24
40
76
8.194 
0.274 
N/R
1.64
25
41
70
6.871 
0.246 
N/R
25
41
72
7.250 
0.200 
25
41
76
8.006 
0.086 
1.63
24
39
68
6.785 
0.160