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 
24
39
70
7.163 
0.113 
24
39
74
7.918 
-0.002 
1.61
23
37
66
6.698 
0.073 
23
37
68
7.076 
0.026 
23
37
74
8.207 
0.287 
N/R
1.60
25
40
70
6.974 
0.349 
N/R
25
40
72
7.352 
0.302 
N/R
25
40
76
8.107 
0.187 
1.59
22
35
66
6.988 
0.363 
N/R
22
35
68
7.365 
0.315 
N/R
22
35
72
8.119 
0.199 
1.56
25
39
68
6.698 
0.073 
25
39
70
7.076 
0.026 
25
39
76
8.207 
0.287 
N/R
1.52
23
35
66
6.900 
0.275 
N/R
23
35
68
7.277 
0.227 
23
35
72
8.031 
0.111 




 TPS adjustment

The TPS (Throttle-Position-Sensor) is an important part of the XC setup.  It effects how lean you can go in the mid-range especially, because it controls how fast the spark advance curve comes in.  There have been a good number of reports coming in about part-throttle detonation, (knock), on all of the XC motors, (and even overheating on the XC600).  The detonation is aggravated by leaning the mid-range (lowering the needles), and also by installing heavier clutch weights (puts more load on lower rpms).  So you need to consider your overall setup before you make big changes in the jetting.  Even if you are not changing your jetting I recommend resetting the TPS sensor.  Our 2002 XCs run much better after this adjustment. 

Does your XC500 or XC600 have a roughness at 5000rpm?  Or does your XC700 or XC800 have a "clatter" at 5000 to 6000rpm?  Almost all 2002 XCs have these symptoms, and it is because the factory TPS setting is too high.  Readjusting the TPS will make your XC run smoother and safer at low speeds. The best way to adjust the TPS setting is to use the Polaris TPS Tester #2201519. The wire harness and the regulator are included in the kit. The VOM and the 9V battery are not included. You also will need a "tamper proof" T25 Torx bit to adjust the TPS sensor, (or you can drill out the center of a standard T25 bit)..

Important Recomendation: On all XCs with the TPS sensor, (500, 600, 700 & 800), set your TPS voltage (using the Polaris TPS tester or a homemade substitute) to Not More Than 4.0 volts at WOT. Some XCs have come from the factory with much higher TPS voltage settings, and these seem to be the ones reporting part-throttle detonation.  


 

 Carb Boot Mod - American Built Twins

LOW $$$ HORSE POWER FOR XC SP 500-600-700-800'S

What you are doing is removing the reed stuffers , opening up the carb boots to a "v-force DELTA 2"size rectangle , have them checked on a flow bench (IMPORTANT !!! YOU MUST HAVE BOTH BOOTS MATCHED WITHIN 1 CU. FT. OF AIR FLOW!!!).The results are about 4 H.P. increase on a 01/02 600 !

This mod should be the first thing you do to inprove your sleds proformance-works great with stock reeds!Do not open the boot larger than a v-force pattern or they will loose too much strength.

BEFORE AND AFTER PICS OF CARB BOOTS 

Any one that does cylinder porting should be able to handle this mod for you....just make sure that they flow bench those suckers and match 'em for you!

Also...a boost bottle (SLP PLASTIC BOW-TIE STYLE)really helps clean up the bottom end on these twins.Gets rid of all that fuel spit-back in your air box...but POLARIS left no room on the '03 models for one...still helps on the '01-'02's....forget your drills and razor knife when installing-just use a well oiled 3/4" hole saw for a perfect cut !

 


 Establishing a Jetting Baseline

Regardless of whether your sled is bone stock or you have added some accessories, one of the most important pieces of information you need for consistent peak performance is to establish is a “jetting baseline”. This is when you fine-tune and jet your carburetors for a specific set of conditions. Once you determine a baseline for your exact intake/engine/exhaust combination, you can use the data to properly calibrate your jetting for whatever conditions you may ride in. This procedure is especially valuable for unique combinations that deviate from the factory supplied jetting charts.
You will of course want to start with the jetting recommendations supplied by the manufacturer for your exact model. Normally, your sled will be jetted for conditions colder than what you’re likely riding in to maintain a “safety margin”. If you have added aftermarket accessories, follow the recommendations supplied by that vendor. If they do not supply any suggestions, always err on the rich side.


While more precise tuning can be performed using exhaust gas temperature gauges, you can perform very accurate tuning by simply analyzing the spark plugs and the piston wash. Many tuners will simply learn to read spark plugs, as this is clearly the quickest and easiest method.


At the time of your testing, air temperature and elevation, at a minimum, are required to determine your baseline specification. Better yet, what you’re really interested in is Relative Air Density, a reading that is a combination of air temperature and barometric pressure. You can determine the proper jetting for your sled at a given temperature and elevation, but if this was performed when a low pressure air mass was present, you could be too lean at that same elevation and temperature if a high pressure air mass passes through. A higher barometric pressure means that the air is denser, and there will be more molecules of oxygen entering your engine, thus a leaner fuel/air mixture.

An air density guage can bepurchased from most leading performance shops. (Part #725-160 for $129.95 from Hi-Performance Engineering at 218-681-2390 or 1-800-451-5268


Make sure your machine is good and warmed up by running it for a while before beginning any calibrations. You want to safely operate the machine at wide-open throttle for at least 1/4 mile on a flat, well packed surface. While at full throttle, shut off the ignition before releasing the throttle. When the sled comes safely to a stop, examine the spark plug color, piston domes, and even the exhaust manifold to determine if the mixture is rich. Because of the differences in engine designs and hundreds of performance products available for these engines, you may want to contact a dealer or performance company that is familiar with your engine combination and talk to them about any specifics you should be aware of when “reading” your plugs and pistons.
Generally, if the spark plug insulator (white porcelain surrounding the center firing electrode) is dark brown or black, the mixture is too rich. Hopefully you are familiar with the desired color you’re looking for; it could best be described as the color of cardboard, a light to medium brown. Very light brown, gray or white is too lean!
Another valuable indicator on the spark plug is the center firing electrode; as the plug color starts to lighten up when properly jetted, the center firing electrode will start to have a “silver” tip, or crown. As the mixture becomes leaner, this silver crown will start to creep down the side of the electrode; this is your target. This metallic appearance on the end of the electrode should not extend any further than 1/4 - 1/3 of the way down the tip. Many tuners are happy with the margin afforded by simply seeing the silver tip; then they’re close enough for trail riding with a bit of margin to spare.


The ground electrode is also an indicator; on many engines you will see a “shadow” (darker area) just up to the radius (bend) that will usually coincide with the color and firing electrode appearance. If this shadow is further down the ground strap towards the plug threads, you’re likely too lean. If this dark shadow is all the way across the strap to the center of the plug, you’re too rich.


Use all three of these plug indicators; try not to rely on only one. Color is likely the easiest and most widely used, but looking for the metallic crown on the tip of the firing electrode is a very accurate indicator on most engines; just don’t ignore the other indicators. When experienced, many tuners can recognize a properly jetted sled simply by listening to the tone of the engine. They always verify their instincts, but they can get really close before they perform final fine-tuning.
(This same procedure can be used to tune the needle position, but you would want to maintain a 1/2 throttle position for a 1/4 to 1/2 mile, again hitting the kill switch before releasing the throttle. This distance will ensure that the color you are seeing is caused by the carb fuel circuit that is responsible for that throttle position.)
It is best to reduce main jet sizes very cautiously and carefully to avoid piston and cylinder damage. If you are way off, reducing the main jet two sizes at a time may be acceptable, but once you start to get close, only reduce the mains one size at a time. When the engine performance is clean and the spark plugs reach your desired state of tune, record your environmental conditions. Again, at a minimum, record the temperature and elevation. Better yet, the Relative Air Density (if you have access to a gauge).
Now you have established a baseline. Anytime the elevation and /or temperature (air density) changes, you can compute the changes needed to your main jets to maintain a similar state of tune. There are several mathematical systems available to properly determine the required change, so we’ll cover some of them.

Relative Air Density
This is going to be your more accurate method. The higher the state of tune your machine is in, the more seriously you should consider this method. Let’s say that when you get your engine running cleanly and the plugs are looking right, you were using 360 mains and recorded the air density at 80%. Next weekend you find the air density to be 88%. You know you have to jet up, but how much?
Divide the “new” air density by the “old” air density, then multiply this factor times the “old” jet size. This would be 88 (new density) divided by 80 (old density) which is 1.1; multiply this times your old jet size (360) and you get 396. Rounded up (5 and over round up) to the next jet size, you will need to install 400 mains to maintain your fuel/air ratio. It’s that easy.

Temperature/Elevation
The majority of tuners will simply rely on air temperature and elevation, and for stock machines this method is tried and true. If you know the main jet size that was right on the money for a given elevation and air temperature, you can use “Jetting Correction Charts” to mathematically determine what changes will be required to maintain your state of tune.
Arctic Cat uses a “Temperature/Barometric Pressure Chart”, Ski-Doo references a “Carburetor Main Jet Correction Chart”, both of which can be found in their respective Racing or Performance manuals.
Holtzman Engineering has generated a set of “Jetting Factor Charts” which are extremely valuable. These charts provide a “jet factor” for different altitudes and temperatures. This “factor” can be applied to any jet size at any given altitude and temperature to arrive at the correct jet at any other set of conditions. This factor includes the affects of the pilot and needle jet on the overall total fuel delivery.

JETTING FACTOR vs. ALTITUDE AND TEMPERATURE

MIKUNI HEX JETS


MIKUNI ROUND AND KEIHIN HEX JETS


Once again, an example might help. Let’s say we have a Mikuni hex main jet installed of size 300 and the sled runs well at an altitude of 8000 feet and –20 degrees F. What size jet would we need for an altitude of 3000 feet and +20 degrees F? The Mikuni hex jet factor for the first set of conditions is 0.79; that for the second set of conditions is 0.85. The formula is very similar to the Relative Air Density formula; “new jet factor” divided by “old jet factor” multiplied by the “old jet size” equals “new jet size”. The new jet size therefore is 0.85 (new jet factor) divided by 0.79 (old jet factor) times 300 (old jet size) equals 322 (new jet size), so we would use a size of 320 to maintain a similar fuel/air ratio.
If the carburetor had been a Keihin with a hex jet size of 160 at 8000 feet and -20F, what size jet would get us to 3000 feet and +20F? The jet factor for the first set of conditions is read from the graph on the right above and is 0.89; the factor for the second set of conditions is 0.92. The new diameter numbered jet size is therefore 0.92/0.89 * 160 = 165.
Needles are usually moved one clip for approximately every 20% change in Mikuni hex jet size or every 10% change in diameter numbered jet size (Mikuni round jet or Keihin hex jet). For temperatures or elevation in between these charts, it is fairly straight-forward to determine the proper jet factor. The jet factor for a Mikuni hex jet at a temperature of –10 at an elevation would be between 0.85 and 0.83; that would be 0.84.
Holtzman has also developed jetting charts that display required jetting reduction as a percentage for use with their Tempa-Flow and Vari-Flow float-bowl pressure regulator compensators that are capable of changing the effective jet size; a combination of the needle jet, main jet and pilot jet. These devices compensate all the way down to 1/4 throttle by changing the pressure across the jets, a very effective method of broad-band jetting correction very similar to the method used by the Ski-Doo DPM system.
Many engines with broad fuel curves (like most Yamahas) will not make any more power as you jet down from a certain point, and basically make the same power across a three-four jet size spread. Another consideration is that an engine under heavy load will require more fuel; riding after a wet, heavy snowfall will require more fuel for otherwise identical conditions than a flat, hard surface. Your engine will also run cooler and safer if you error slightly on the rich side. Error on the lean side and you could find yourself walking home or hitching a ride.
Once you have properly jetted your sled once and know the conditions, you can use that information to determine the proper jetting for just about any different condition you may ride in. You can also use these formulas to determine how much of a safety margin you may have for a given set-up; if you know what jetting really makes ‘er sing at 0 degrees, you can easily figure out how far you have to jet up to be sure you are safe down to –30, or whatever! Use this knowledge to be your fastest when needed (competition), and to give yourself some margin when you need it (longevity). Remember to always check your specific set-up with piston, plug, and/or EGT readings, and start out on the rich side and work your way down.


Snowmobile Jetting Procedure

by Allen Roberts, Starting Line Products

One of the best field jetting procedures comes from Allen Roberts, a leading calibration technician with Starting Line Products in Idaho Falls, Idaho. Starting Line Products provides very detailed calibrations specifications with their performance products, due in part to the testing procedures.
“Before performing a jetting calibration, the fuel system must be inspected for cleanliness and the carburetors should be checked for proper float height setting. Another very important item is carburetor synchronization. If the carburetors are not properly synchronized, the throttle response will be very poor and this can plug fouling. I prefer to use the “Uni-sync” carb synchronization tool (available through SLP for $36.08, part #20-81). Using the Uni-sync, adjust the idle screws to synchronize the carburetors at idle. Loosen carb cable adjustment to ensure slides are bottoming on idle screws. Then check that the throttle slides are moving from the idle screws at the same time when the throttle is opened. If throttle slides are not opening together, lengthen or shorten the cable adjustment at the top of the carburetors.
The low speed tuning (idle to 1/4 throttle setting) is calibrated by pilot jet changes and adjusting the air screw. Operate the throttle between idle and 1/4 and see if the engine revolutions increase smoothly. If the pilot jet circuit is too lean, increase in the engine speed will be slow and irregular. If the pilot jet circuit is too rich this would create heavy exhaust smoke as well as a dull exhaust noise. If you cannot maintain speed in this 1/4 throttle area while the throttle is held constant, the pilot jet circuit is too lean.
To find a good starting point on the air screw, warn up the engine to operating temperature and adjust the air screw in (richer) or out (leaner) until the idle RPM is at its highest point (do not open more than three turns). One point to watch on air screw adjustment, if the engine idle to 1/4 throttle performs best with the air screw adjusted 1/4 turn or less it may be an indication that the pilot jet is too lean and the opposite holds true if the air screw ends up near three turns the pilot jet may be too rich. It’s easier to adjust the airscrew than to change pilot jets to find out if you are too rich or lean on the pilot circuit.
The mid-range tuning (1/4 to 3/4 throttle) is calibrated by the needle jet and jet needle. The jet needle tapers off at one end and the clearance between the needle and the needle jet increases as the throttle valve opening gets wider allowing more fuel in to the carburetor venturi. The air-fuel mixture ratio is controlled by the height of needle positioning clip that is inserted into one of the five slots provided in the head of the needle. The top slot #1 is full lean; the #5 slot is full rich.
The needle jet is changeable in most Mikuni carburetors. The fuel delivery can be adjusted by changing to a larger or smaller inside diameter, the size designation will have a letter followed by a number example, P-2. The number shows the inside diameter size in increments of .010 mm. Example, the difference between P-2 and P-4 is that the inside diameter of P-4 is .010 mm larger than P-2. The letter shows the inside diameter size in increments of .050 mm, the difference between P-2 and Q-2 is that the inside diameter of Q-2 is .050 mm larger than P-2. So a larger diameter needle jet will allow more fuel to pass or a richer mixture.
Dialing in the pilot circuit can normally be accomplished by listening, seeing and feeling what the sled is doing, but above 1/4 throttle the horse power and engine loading is increasing rapidly and the chances of engine damage because of improper jetting increase as well. So it becomes necessary to start reading plug and piston color. The best way to get a valid piston/plug reading is to hold the throttle steady at what ever throttle setting you want to check and run at that setting for at least 1/4 mile if possible, kill the engine before releasing the throttle.
A couple of tips on mid-range jetting, start out conservative, it is easier and less expensive to change jets than a seized piston. Use the jet needle for changing fuel requirements first; it’s faster to change the "E" clip position than to change the needle jet. If you find yourself at full lean or rich and still needing more or less fuel that is the time to change needle jets. A rule of thumb here is one "E" clip position on the needle is equal to one needle jet size. So if your needle jet is a P-4 and the needle "E" clip position is #1 you could change the needle jet to a P-2 and move the needle clip to #2 and the fuel flow would be real close to the same as the P-4 and #1 clip position.
The tuning procedures for the main jet are the same as the mid-range except the throttle range will be 3/4 to full and of course you will be changing the main jet not the needle jet or needle.
After you have completed jet testing and are happy with the results, you would record the air density (or temperature, barometer and elevation) for that day. This will be your “base air density” and “base jetting”. When the weather and/or elevation (air density) changes use the Relative Air Density formula or a jetting correction chart to determine the proper jetting change.”
Starting Line Products can be reached at 208-529-0244 or on the web at www.startinglineproducts.com. They specialize in designing, manufacturing and calibrating performance products for snowmobiles.


  AIRBOX TEMPERATURES

One of the more curious aspects of a snowmobile is the variation of intake temperatures. Here we have a carbureted snowmobile, with jetting that is calibrated to supply sufficient fuel for, say –20 degrees. At cold start-up, the jetting may even be a slight bit too lean on the bottom, requiring a blip of the choke.

As the ambient air temperature warms, the jetting and fuel delivery remains fairly constant (there is some slight compensation). Your engine that was properly jetted for –20 can actually be running quite rich at 20 above.

Now consider the effect of heating the incoming air. Why, or how? Many sleds, maybe without your knowledge, warm the incoming air before it enters the engine. The thermometer may say –20, but your sled is sucking warm air from under the hood that can be much warmer. The key here is the inconsistency and variation that can occur. Your jetting may be even further off than you ever realized; depending on the intake design and operating conditions. Deep snow, heavy load running at slow ground speeds can be a prime example of how the airbox intake temperature can vary wildly from the actual air temperature.

By placing a temperature-based float bowl pressure regulator like the Holtzman Tempa-Flow in your airbox, carb jetting is adjusted as actual airbox temperature changes. The factory recommended jetting specs take all of this into account, but the fact remains that the actual air temperature inside the airbox can be fluctuating more than you realize.

Sucking warmed air into the engine isn’t all that bad in certain conditions. The venturi effect speeds up the air as it enters the carb, and the result in high humidity conditions can be icing of the carbs. Yamaha for years has liked to blend warm, under hood air with colder, outside air to help keep the carbs free and clear. On most Arctic Cat models, the airbox intakes, located above the foot wells, are ingesting an amount of warm under hood air exiting the rearward outlet vents.

Testing has indicated the airbox temperatures can be as high as 30-40 degrees warmer than the actual air temperature. Could this maybe explain why some sleds get such poor fuel economy? EFI and DPM equipped sleds have airbox sensors, and the result is improved fuel economy and performance as the fuel delivery is far better matched to changing air temperature; ambient air temp and incoming airbox “blended” air temp. While there may not be much you can do to better regulate this wide ranging variable, there is something you can do to compensate for its affect; install a float bowl pressure regulator based on temperature like the Tempa-Flow from Holtzman Engineering (715-479-8727).

The $148 Tempa-Flow attaches to the carb float bowl vent lines and regulates the float bowl pressure by sensing the air temperature. It applies no pressure correction at –20; any temp warmer and it reduces float bowl pressure. Jet your sled for –20, and the Tempa Flow does the rest, providing improved fuel economy and performance. Since it is a mechanical device, it doesn’t react as quickly as an electronic system like DPM or EFI, but it will keep the jetting far closer to ideal than before.

Sleds that already route the vent lines to the airbox will require little, if any, jetting changes and are prime candidates for placing a Tempa-Flow in the airbox. However, if your vent lines are not currently routed to the airbox, a significant increase in main jet size may be required if you relocate the vents to the airbox due to the loss of under hood pressurization of the float bowls.

This is a logical product that provides real world benefits on sleds that have no temperature compensation.



Pipe Temp and Airbox Pumping

A cold pipe can keep your clutch from hooking up, because its lower resonant frequency peaks the engine at lower rpm than the clutch is set for. That's worth avoiding. Pipe temperature effects can also produce inconsistent and therefore useless dyno results - also worth avoiding.

The airbox used to be just an intake silencer and a place to put the air filter. Now it's much more than that, so read on before you gut or toss your box. Just as is being done on new cars and motorcycles, snowmobile airboxes and their intakes are being built as resonant systems. When the airbox is resonating strongly, driven by the engine's suction pulses, its rapid internal pressure fluctuation covers a range of plus and minus 10-15%. This is just like the resonance of a bot
tle when you hum into it. If your engine's intake events run in step with the positive side of this resonance, it's just like getting a 10-15% supercharge boost for free. That's worth having. And what if you modify your engine, raising its peak-power rpm beyond the range of the airbox resonant frequency? There is a simple relationship you can use to alter airbox frequency by changing the length and/or diameter of the airbox intake pipe(s). That's worth having.

PIPE TEMPERATURE EFFECTS Image

Why are pipe temperature effects important now? Back in the 1970s no one had ever heard of such a thing. What's different now?

In the search for horsepower, tuners have built pipes with ever-larger suction horns. Back in the 1970s, it was common for the ratio of header-pipe minimum cross-sectional area to center section area to be in the range of six or seven to one. If the header pipe was 40 mm, the center section was around 100 mm. As tuners have learned that stronger pipe suction and bigger crankcase volumes make more power, they have increased pipe suction by increasing this area ratio to values over ten to one and still climbing. This means that a 40 mm head pipe now feeds into a chubby center section of more than 125 mm in diameter.

The 2001 Arctic Cat ZR 500 is the first consumer sled to feature exhaust pipe temperature based ignition timing compensation. A temperature sensor fitted to the center section of the exhaust pipe feeds data to the ignition system, which selects the best timing curve to stabilize the engine performance for maximum performance and consistency.

What's the point? As center sections have grown fatter, their surface area has increased just as much, so any cold air reaching pipe surfaces cools them much more strongly than it did 20-30 years ago. Also and obviously, the use of separate pipes for each cylinder increases total pipe surface area even more. Therefore if you have a big bunch of black steel bananas under your sled's hood, you have the makings of a pipe temperature problem.

It works like this. Your engine's rpm of peak torque comes at the rpm where the return pressure wave from your pipe's final cone arrives just as the exhaust port is about to close. Fresh charge that has been pulled by pipe suction through the cylinder and out into the first part of the header pipe is now forced back into the cylinder by this reflected wave. This supercharge is what produces maximum torque in the engine. Its arrival time is determined by two things - the distance from exhaust port to the tuning point in your reflector cone, and the speed of sound in your pipe.

The length of your pipe doesn't change, but the speed of sound inside it very definitely does. Because sound is propagated as a wave through actual collisions of gas molecules with each other, its speed depends directly on how fast those molecules are, on the average, moving. The temperature of a gas is a measure of that average molecular velocity.

Pressure is much less important, because it does not affect molecular velocity. We aren't talking about a small effect here. In the very hot gas that jets from the cylinder just as the port opens, the speed of sound may be 2500 feet per second (fps) instead of the 1087 fps that is the velocity for so-called standard conditions. In the coolest part of your pipe, where the gases have expanded considerably, sound velocity may still be over 1400 fps.

Exhaust flow is extremely turbulent, and turbulence is a highly effective way of increasing heat flow between a fluid and the walls of its container. Therefore anything cooling the outside of the pipe also cools the gases flowing inside it. Those of you with dyno experience know that cold-pipe and hot-pipe dyno runs give different power, and at significantly different rpm. Now think about whether or not the "weather" around your pipes is the same on track or trail as it is inside the hot dyno room. Same? Or maybe pretty different?

Please bear in mind that when I refer to pipe temperature, I do not mean exhaust gas temperature, or EGT. EGT is measured in the head pipe, up as close to the exhaust port as possible, by a probe that sticks into the pipe to measure gas temperature only. EGT gives us valuable information about combustion. Pipe temperature, on the other hand, is just what it says it is - the temperature of the metal pipe itself. We are interested in pipe temperature because it tells us whether or not the pipe is hot enough to put the rpm of peak torque where it belongs. We measure pipe temperature on the outside of the fat center section of the pipe because this is the region - with all its large surface area - that is slowest to heat up and fastest to cool off.

Remember the ‘99 Arctic Cat ZR 440 race sled? It had a hot/cold rocker switch on the bar. At the start of a race, when the pipes are cold, the "cold" position switched the timing to a retarded map, thereby dumping more heat into the pipes to correct for their low temperature. The higher EGT of retarded timing also brought pipe temperature rapidly up to operating range. Once this was achieved, the switch would be flicked to the "hot" position, which would reduce EGT and give maximum hot-pipe performance.

It all started with the 1999 Arctic Cat ZR 440 race sled. A handlebar mounted thumb-rocker switch allowed the driver to select a “hot” or “cold” position to manually change the ignition timing to help build pipe heat for stronger acceleration.

For the 2000 ZR 440, Arctic made this system automatic as their "EPTS", or Exhaust Pipe Temperature System. Five ignition maps, covering the requirements of the pipe in stages as it warms up, are selected by the ignition computer, based upon a temperature-sensing thermocouple on the pipe center section. When the pipe is hot, the ignition is retarded approximately 5 degrees. A retarded ignition releases more heat into the pipe. This does two things. First, it makes the pipe work right now by compensating for the cooling effect of the cold pipe metal with hotter exhaust gas. Second, that hotter exhaust gas quickly heats up the pipe. As the pipe heats up and the speed of sound in the gases in it rises, the rpm of peak torque rises. To keep it from rising beyond the clutch set-up, the ignition computer switches in successively more advanced timing maps to reduce EGT, thereby keeping the rpm of peak torque close to constant.

Now the 2001 ZR 500 consumer sled will have a similar EPTS system. Does the retarded timing lose horsepower? No, it gains in power-to-the-ground because more is gained by keeping the engine working with the clutch than is lost by not pushing the timing to the bitter end. The curve of ignition timing versus torque is more like a round-topped hill than a spike - a little retard has a pretty small effect.

I spoke with Arctic Cat engineer Greg Spalding. He said, "Three or four years ago I looked at getting the pipes hotter to accelerate faster on our 440. Initially I tried a retard button, with some special Kokusan (ignition manufacturer) equipment capable of retarding the ignition as much as 40 after top. We found that twelve degrees after top held it at 5000 - that really put some heat into the pipes - like 1300 degrees. Then we translated that into the hot/cold rocker switch, and now the five-map system with the pipe temp sensor.

REAL WORLD VERSUS THE DYNO

Nine years ago 500 cc Grand Prix motorcycles appeared at the US GP with carbon-fiber cases over their exhaust pipes. When I asked what the purpose of the cases was, I was told that they brought dyno and track performance closer together, and prevented the pipes from cooling off during off-throttle sections of track enough to hurt acceleration.

Aluminum clamshells and insulating heat wrap are widely used to provide a greater level of consistency to pipe temperatures. As an added benefit, the “shell-noise” of the exhaust system is also reduced.

We have all seen dyno setups in which the pipes stick out of the engine every which way - one right in front of a cooling fan, another somewhere else. Back in the days of small-diameter pipes this used to work semi-OK, but now that fat pipes lose heat so fast and take so much time to warm up, dyno testing has to make allowance for pipe temperature and/or cooling effects. If it does not make such allowance, any gains made on the dyno may not translate to the snow.

Another effect many of you will be familiar with is inconsistent performance from aftermarket twin or triple pipes. The people developing such competition-oriented pipes assume their users will be hard on the throttle all the time, keeping the pipes hot and therefore working as they should. Users who aren't hard on the throttle may be disappointed, because big individual pipes cool right off under those conditions, under-peaking the engine.

Why worry if the engine under-peaks by a few hundred revs? Here's why. Every system on the engine is designed for operation in a specific rpm range - the intakes, the airbox resonance, the porting, and the clutch. If the engine doesn't reach the rpm these systems are designed for, don't expect them to work at their best. You want a symphony from your engine, not Dixieland.

Savvy tuners are now realizing that they need to know how hot pipes must be in order to work right. Working perfectly in a hot dyno room during summer development sessions is no guarantee that those pipes will reach that temperature with big clouds of Wyoming powder snow hissing onto them, mixed with frigid 20-below air. Solving this problem means (a) measuring the temperatures of pipes when they are working properly, and (b) taking steps to make sure they can reach that same temperature on your sled, in the field. That means either (a) creating an automatic system as Arctic has done, or (b) measuring pipe temperatures in the field and finding effective means of raising them to the design point - limiting air access to the cowl, wrapping the pipes or parts thereof, or installing pipe covers.

Exhaust system center sections have grown increasingly fatter over the past few years. This increases the pipe suction and resulting power output, but the increased surface area makes the exhaust more susceptible to the affects of cooling.

BACK TO THE AIRBOXImage

Any hi-fi enthusiast knows that woofer enclosures work best when the resonant frequency of the enclosure is nicely centered on the speaker's response range. The enclosure usually consists of a sealed volume with the speaker installed in one of its walls, and an opening, called a reflex port, cut into the enclosure. A resonant system consists of a mass, which vibrates back and forth against the restraint of something flexible, like a spring, with an excitatory force to drive it. In the case of the speaker enclosure, the mass is the air in and within one diameter's distance of the reflex port. The spring is the compressible air inside the enclosure. The system is set into vibration by the amplifier, driving the speaker cone back and forth as a piston.

In the case of an engine's intake airbox, the mass is the air in the airbox inlet pipe(s). The "spring" is the compressibility of the air in the box. The excitatory force - a very powerful one - is the endless sequence of strong engine intake suction pulses from the carburetors. The airbox must not have any significant leaks, as the throttled, back-and-forth airflow through them acts like a hand on a vibrating bell (anyone who's ever tried to play low notes on a valved wind instrument knows what a killer leakage is). The airbox inlet pipe is usually made with a smooth bellmouth on either end to reduce flow losses. Carburetors or throttle bodies must likewise seal positively to the box. When a system like this gets to humming, the pressure inside it vibrates rapidly plus and minus 10-15% of atmospheric pressure. In fact, the humming is so powerful that in many cases a sub-resonator is placed near the atmosphere end of the inlet, to prevent radiation of this powerful honking sound to the outside. EPA objectors are always waiting there with calibrated sound meters and spectrum analyzers ready.

How can you adjust the resonant frequency of your airbox if you raise your engine's peak-torque rpm with pipes or porting? One way is to invest $30,000 or so in professional wave dynamics software like Ricardo "Wave", running on a $10,000 Sun workstation. Probably on the right back street in Hong Kong you can pick up a pirate copy for $25, but which street is it?

The airbox inlet tubes, or “horns”, are specifically designed to provide a resonance that can increase the total airflow by up to 10-15%. Removing these can cause the engine to loose power and increase the intake noise.

We're so used to the idea that problems have to be solved with silicon logic that we forget about steel and aluminum solutions. “Wave” is great if you have a tricky fuel mixture glitch with #7 cylinder in your Ford NASCAR engine. But with a simple formula that tells us which variables push the airbox frequency which way, and by approximately how much, we can devise dyno experiments that will get us the answers we need - without those expensive Cathay-Pacific coach tickets.

Here is the formula.

(Airbox Frequency), squared, is proportional to inlet pipe area/(airbox volume X inlet length) This is useful because it shows us that if we want to raise airbox resonant frequency, we must increase inlet pipe area or decrease airbox volume or inlet pipe length.

AN EXAMPLE

If our present engine is a twin, giving peak torque at 8200 rpm, that is 8200/60 = 137 revolutions per second, or 137 X 2 = 273 suction pulses per second. Unless there is some special problem, the airbox will be designed to resonate near that frequency.

If we now want to raise peak torque revs by 10%, to 9020 rpm, we must also raise airbox frequency by a similar amount. If we raise airbox frequency by 10%, its square will increase by 1.1 X 1.1 = 1.21 times, or 21%. That means that whatever is on the right-hand side of the equation must also increase by a factor of 1.21. Take your pick.

You can:

(a) increase inlet pipe area 21% (that is, increase its diameter by 10%) or,
(b) decrease airbox volume by 21% or,
(c) decrease inlet pipe length by 21%

Because these systems generally work better the bigger you make the airbox, we won't try (b). Since we are raising revs and power, increasing inlet area looks pretty good, so we could choose option (a), increasing inlet pipe area. However, option (c) would appear to be the easiest. Before we go to the dyno, we'll make up a few airbox inlet pipes to give us some test choices. Then we can run through our tests quickly and zero in on the sweet spot. Each end of the box inlet pipe should have a smooth bellmouth.

Likewise, go carefully before removing internal airbox "furniture". Assume nothing, but test with each change to understand its effect. Airbox designs are sophisticated now, so their internal features often have functions.

Any resonant system always has anti-resonances. In the case of an airbox, that is an rpm at which the engine breathes from the box when pressure is at the low part of its cycle. What if there's an anti-resonance right where you want your clutch to engage? Of course you could imagine a system with a variable-length inlet pipe to deal with this, but the easy way is just to kill the anti-resonance by opening a big hole in the airbox. Systems of this type are in use on certain sports motorcycles. When the engine runs near the rpm of the anti-resonance, the engine control computer tells a little motor to open the airbox port. When it revs up, the motor closes the port.

Isn't life getting complicated?



Torque or Horsepower?

This subject is definitely confusing more than just the regular tuners. Some experts have lately pronounced that "Torque Doesn't Matter," you need only be concerned with maximum power.

To end the confusion right now, let's set the record straight: for maximum performance you clutch for maximum power, but it does matter a great deal what your torque curve looks like if you want an automatic belt transmission to work well enough to keep you on that power peak. It's easy to forget that your limiting factor is how well your transmission works, and that the modern snowmobile uses a torque-sensing helix cam to help keep the correct pressure on the belt. Understanding how the torque-sensing helix works is the key to understanding clutching.

The torque-sensing helix was introduced into the world of snowmobile transmissions in the late ‘60s, and made an immediate difference on belt life and efficiency. Belt life instantly doubled and efficiency gained an easy 10%. You not only had 10% more power to the snow, but whereas you previously could only transmit 35 hp, you could now easily transmit 70 hp without belt problems. Later improvements in belt construction and the introduction of Kevlar cords almost doubled that figure again, and that's pretty much where we are today. The "torque-sensing" helix adjusts the side pressure on the belt according to the torque the engine produces. Depending on the angle of the helix, a certain part of the torque can be converted into side pressure. The smaller the angle, the more belt side force it generates. This is why "Torque Backup" is important. Torque backup is the difference between the lowest rpm with maximum torque and the rpm at which maximum power occurs.

In order to make a snowmobile accelerate and maintain top speed, there are a number of forces always trying to slow it down. You are fighting inertia, friction and drag, all of which try to pull you off the power peak. This is why it is important to have a powerband where maximum torque occurs at a lower rpm than the maximum horsepower peak. With good torque backup, the secondary helix feels an increase in torque as drag tries to pull the rpm down. With increased torque feedback the secondary drive will start to push the belt into a lower ratio, actually changing to a "lower gear,” which will maintain the engine speed at the horsepower peak.

This is where a lot of confusion starts, mainly because it is not easy to understand what the difference is between torque and horsepower, and there is a BIG difference. Torque is the result of the gas forces above the piston working on the crank arm and creating a momentum. This momentum force can be measured on the dyno brake and is usually given in foot-pounds. Work is something different. It is a question of how often in a given time period you can lift a certain weight. The more times you can lift a weight in a minute, the more work you produce. The same with an engine. Torque tells you how big a load you can lift, and the rpm tells you how often you can do it in a minute.

The horsepower curve is a result of multiplying torque load with engine speed to find the optimum combination of load and speed that will produce the most work. Therefore, the horsepower peak is a purely theoretical figure. It only tells us at what part of the rpm band we have the best chance of producing the most work.

The components in the drive train cannot "feel" horsepower, but they can "feel" speed through the flyweight mechanism and react to torque through the secondary helix cam. It is possible to make an engine with such a narrow powerband that the torque peak falls almost together with the horsepower peak. In these cases the torque must fall faster as the engine speed increases, and by definition this gives a very narrow powerband. Not only does the power fall fast as the engine revs beyond the horsepower peak, but this has almost the same effect as throwing on the brakes when the engine overrevs. As the speed then decreases, so does the torque, and with less torque feedback there is no backshift into a lower ratio to compensate. This results in an engine and a clutch that live in disharmony, constantly chasing each other around, trying to agree on a place to coexist.

If, on the other hand, the torque curve is flatter with a peak at least 500 rpm below the horsepower peak, this usually also means that the power does not fall off as fast when the engine revs beyond the power peak, and instead of the power dropping off, it still pulls hard. When the rpm drops, the torque then increases to downshift you into a lower ratio while maintaining the engine at a power peak. With the engine pulling hard beyond the power peak and downshifting with increased load as the rpm goes down and the torque increases, you have a very happy coexistence between the engine and its transmission. The wider the torque backup, the easier the engine is to clutch. Having maximum torque down lower on the powerband also gives great acceleration out of corners and off the line. Hard acceleration is used in 90% of your trail riding, while there are fewer places where just sheer top-end is needed. This has given us a place for the "Trail Torquer" pipe that fulfills just those conditions. With strong midrange, a wide torque band and hard acceleration, they make trail riding even more exciting.

The engineers who develop your snowmobiles have to take a number of factors into account when determining what kind of power plant to use for your machine. This depends on the weight of the machine and the kind of driving it is intended for. The heavier the machine is, the wider a torque band you need to make it work right. A larger, long-stroke twin engine may be a better choice if you run a lot on tight trails, because it combines good torque with light weight. A good example of this is the popularity of the Arctic ZR 700 (and other big-bore sleds with wide powerbands). Good acceleration out of corners and good clutching is the reward for this combination. A triple engine will weigh more and produce more power at a higher rpm, and this can be used to advantage on lakes and in oval racing, drags, and speed runs where the demands for abrupt on-again/off-again acceleration is less. How much of a compromise between maximum power and a strong torque backup you need for your type of riding or racing often determines if you have a successful trail machine or a winning racer. All things being taken into account, you will likely have the most fun and be a more successful racer if you lean toward having a wider powerband and more torque backup.

In our 25 years of snowmobile racing, we have consistently been more successful when we sacrificed a few top-end ponies and a narrow powerband for a wider powerband with more torque backup. "Torque Not Important?" This statement could only be made if you spend most of your time on the dyno instead of on the trail.


 INSIDE Suspension Coupling!

What is "coupling" of the rear suspension and why is it important? What is the difference between "two way coupling" and "one way coupling"?

Suspensions as a whole are nothing but a big bunch of compromises. We'd like the ride quality to be super plush over the small bumps and never bottom out over the big bumps. We'd love to hit the throttle and get total traction with the track not spinning a bit and be able to keep the skis an 1/8" off the ground. We'd like the sprockets to never jump a cog in deep snow, but wear the hyfax at a nice slow rate. It seems as if anything you do to try to accomplish any one of these will compromise the performance in another area. It is all a matter of which combination you feel provides the best value for your applications - what works best for YOU. But first, a little bit of history.

The FAST M-10 was the first true parallelogram suspension. The M-10 introduced coupling to the snowmobile industry and has been the benchmark ever since.

Early bogie wheel suspensions were nothing more than track tension devices with very small amounts of travel, and in some cases no travel at all. The first slide rail suspensions pioneered by Arctic Cat started with about 3" of travel and the ride was improved. When they went to 5" things again got better, but when the travel went above 5-6" the ride didn't necessarily get any better. As engineers kept adding more travel, all the way up to 10" and 11", the ride quality didn't seem to really improve. No matter what the engineers tried, the vehicles didn't seem to work as good as they wanted them to.

Angle Of Incidence:
After developing quite a few suspensions that didn't hit the mark it was finally decided that limiting the "angle of incidence" of the slide rail as it hits a bump was the key factor to further improve the ride quality and make the longer travel suspensions perform. (The "angle of incidence" describes the angle of the slide rails to the ground as it hits a bump. As the front section of the rails hits a bump, the front of the rails rise but the rear of the rails are still at the bottom of the bump, causing the rail to be presented at a specific angle - the angle of incidence. The greater the size of the bump, the higher the front arm will raise and the greater the angle of incidence.) The greater that angle is, the more secondary kick there is to the rider when the rear hits the bump and the greater the loss of control there is to the rider, and greater the loss of speed of the vehicle. Herein is what was limiting the long travel concepts prior to "coupling". It is called many different names, but keeping the slide rails as parallel to the chassis as possible was the answer.

The ideal solution was to be able to carry a specific amount of weight (vehicle plus rider plus energy of the impact) on the rear of the suspension yet be able to limit the angle of incidence. How do you do this? One of the easiest ways to limit this angle was to put a very soft spring in the rear of the suspension. The problem with this solution was that when you land off a jump on the tail (of the sled) the rear of the vehicle bottoms extremely hard. The next round of experimentation was to try to connect the two suspension arms (front arm and rear scissors) together by putting a sway bar between the two arms, and there seemed to be an advantage. The next step was to try to mechanically couple the arms together directly. The arms were connected together via some transfer rods and/or links and some experiments even used cables. There was a huge advantage noticed when the arms were coupled in this manner as the coupling was limiting the angle of incidence.

This is where the parallelogram concept came into being, which all coupled vehicles are a variation of. (Parallelogram meaning; that if you have equal length arms and equal length bars, the link has to stay parallel at all times.) By limiting the movement of the rear arm, both arms would move "together" as a parallelogram, even though only one of the arms actually encountered the bump. The end result is that the suspension rails remain fairly parallel to the chassis.

Front to Rear Coupling:
This type of "communication" from the front arm to the rear is best described as "front to rear coupling". As the front of the suspension hits a bump, the front tells the rear "get out of the way, there's a bump coming!". As the front of the rails start to rise, they are only allowed to rise so far before the rear of the rails begin to move. On a traditional suspension design, this is accomplished by allowing the lower section of the rear arm to only move so far forward - and then stop. This causes the rear arm to move with the front arm (think parallelogram) and pull the rear of the rails up, reducing the angle of incidence and keeping the rails parallel to the chassis. Limiting the forward travel of the lower rear arm pivot is accomplished in different ways on different suspensions, but the end result is the same. On the M-10 it is controlled by the top of the slot, on the Yamaha Pro-Action Plus by the upper gap on the control rods, on a Polaris XTRA-10 & 12 with the F.R.S.S. (front rear scissors stop) adjustable scissor stop blocks, and now Arctic Cat uses a reinforcing cross bar positioned in front of their lower link.

Rear to Front Coupling:

The second side of the coupling is "rear to front" coupling. If you land on the back of the vehicle with a traditional suspension the front arm is independent of the rear arm and only the rear arm is going to be collapsed. To limit bottoming in this situation you have to have enough "spring" to carry the weight of the entire vehicle, the rider, and the forces involved with the impact of the landing. By coupling the rear arm to the front you afford an overall better riding package. After the rear arm has displaced so far (movement to the rear) you stop the travel causing the front arm to start to displace (think parallelogram), but again control the amount of displacement of the rear arm. In effect you are borrowing all of the resistance to bottoming of the front arm shock and spring in addition to the rear arm. This "borrowing" or "combining" of spring rate and shock valving is very similar to what occurs when the front ski suspensions are linked together through a sway bar. Individually, each arm would require a stiffer shock and spring to handle the impact energy all by itself. When linked (coupled) together they can "borrow" spring rate from each other to resist bottoming, allowing the use of softer springs individually. This way you get a softer ride initially, yet a cumulative rate that is more resistant to bottoming when coupled together. This rate combining occurs in both directions of coupling, front to rear and rear to front.

Another consideration of rear to front coupling is weight transfer. By limiting the rearward movement of the arm you are reducing transfer (and traction) but at the same time maintaining ski pressure. For applications where transfer is desirable (drag racing, hill climbing) early coupling of this type is not. This leads to the great compromise of having to choose between ride quality, weight transfer and ski pressure, which can really be a matter of personal preference for your application.

When to Couple and When Not To?:
The timing of when you couple and not couple seems to be part of the magic of what makes one system work better than another. You should not be coupled at all times or the ride quality will be firmer than need be. In this case you are going right past the softer "un-coupled" portion of your travel and are loosing the best ride quality. This is why you can sometimes, on a coupled suspension, find that by increasing the preload of the rear springs that you will end up with a softer initial ride quality. What is happening is that by increasing the preload you are moving the suspension away from a coupled condition to an uncoupled one, requiring some travel to get to the combined rate section of the travel. If you don't have rear to front coupling you have to increase the resistance to bottoming of the rear arm for the tail landing situation. Consequently, when you're not in a tail landing situation the rear arm spring and shock mechanism is stiffer than it needs to be (harsh ride quality). You likely can detect these qualities on those suspensions that do not employ this type of logic. By the same token, these suspensions lift the skis and really hook up well - if that's what you want. What this tells us is that the suspensions that provide the best coupled ride quality do not provide the best weight transfer. When you increase weight transfer on a coupled suspension, you will end up with greater amount of travel that will be softer - maybe too soft which could reduce the overall ride quality.

Current OEM Suspensions

Polaris XTRA-10:
The Polaris XTRA-10 suspension is a rising rate two-way coupled suspension. The black scissor stop blocks on both the front and rear sides of the rear arm provide the limiting mechanism that provides the coupling. It delivers real nice performance in the big bump environment, but compromises much of the lower speed ride quality. Our impressions are that the calibration is intentionally set more for the high speed big bump environment. The adjustability of the coupling blocks on the lower section of the rear arm could be considered a strength but knowing what to do with these blocks when can be a task. One weaknesses of this suspension arrangement is that there's little in terms of friction reduction on the shafts and bushings. In a stutter bump environment the ride quality is just not there in comparison to other coupled designs.

Polaris XTRA-12:
The Polaris XTRA-12 rear suspension is a falling rate two-way coupled system. The obvious strength of this system is the ride quality which seems to be calibrated exactly the opposite of the XTRA-10. Polaris does not seem to be able to get the best of both worlds in one package so they have decided to develop two systems, one for each end of the spectrum. While the XTRA-12 appears to be a parallelogram, the most obvious difference with this arrangement is that the XTRA-12 doesn't have a shock on the front arm. When it comes to comfort, diminishing the effect of the spring and shock on the front arm can afford you much ride quality. By going with this design (eliminating the spring and shock on the front arm) the comfort level has definitely been improved. Initially this design decision may have been more of an attempt at cost reduction as the original XTRA-14 used only one shock in the entire skid frame. What Polaris likely found out with this pilot build of XTRA-14s was that they couldn't get enough work done with only one shock where it was located. In an effort to give the suspension greater bump absorption, a second shock was added to the rear arm to control the energy. What has been gained in comfort by not having a front shock seems to have been lost is resistance to bottoming of the front arm. It may be great for running 40 mph through the stutters, but if you want to go faster through the great big whoops it just can't handle it. Excellent for trail speeds and ride quality, but high speed control and resistance to bottoming is not a strength. Recent tweaks to this design has reduced the ride height of the machines so equipped, reducing the center of gravity and body roll, resulting in noticeable handling improvements. In certain conditions this can be the smoothest riding suspension available; as the speeds and/or the bump size increases, the attractiveness of this suspension diminishes and you will quickly find the limits of the suspension.

Yamaha Pro-Action Plus:
The Yamaha Pro-Action Plus is a true parallelogram suspension with two way coupling. It seems to use a fairly linear rate of shock speed to rail travel. These units are very smooth and since they use a shock on both arms the suspension is able to retain its composure with a bit wider of an operating range into the rough than the Polaris XTRA-12. Still, it appears that in going for the comfort that Yamaha has traded off some of the high speed control of the front arm. This trade off varies from model to model, but it seems to hold true through the line. In our mogul testing this was apparent as the front arm would bottom when we pushed the units hard. There are also a fair share of links in this suspension, and while Yamaha has to be given credit for "sticktion" reduction techniques such as needle bearings and quality bushings, we wonder as to the logic of all the links. We twisted a few of these on our '96 XT and were happy to see the beefy improvements to the '97s, and now the '98s have added a front bumper stop to the rails to provide greater control to bottoming as well as improvements to the center shock to provide better bottoming control. Some of the '97s that were ridden in extreme conditions would damage the front shock as there was no mechanical limiting device other than the rubber stop on the shock itself. The "sliding gap" on both sides of the control rods performs the coupling function on this suspension design. As the front of the suspension hits a bump, the gap at the bottom of the control rods is closed, causing the rear of the rails to move up, keeping the rails fairly parallel to the chassis. In tail landing situations and during acceleration, the gap at the top of the control rods is closed. Once this happens, the front arm will travel up into the tunnel with the rear arm, effectively transferring part of the energy to the center shock and keeping the suspension rails parallel to the chassis.

Adjustments to the control rods take time, requiring replacement or restacking of the plastic shims on the control rods. These are "shop only adjustments", creating a window of opportunity for aftermarket vendors to come up with quicker methods of adjustment. The primary use of these quick adjust control rods is to get more weight transfer, however as the weight transfer is increased there seems to be a fairly proportional decrease in ride quality (the suspension will bottom easier). More weight transfer is obtained by providing a larger upper gap, allowing more weight transfer to take place before the arms are locked together. The Mountain Max versions of this suspension use only 2.5mm spacers in the upper gap for more weight transfer, while the XTC versions of this suspension use 10.0mm of spacers in the upper gap for less weight transfer.

Skidoo SC-10:

Skidoo SC-10 Cross Country Suspension with AD Boivin ETS coupler kit.
Skidoo has their SC-10 suspensions which come in both falling rate and rising rate designs. The falling rate design clearly provides smoother ride comfort yet lacks resistance to bottoming, while the rising rate designs provide good resistance to bottoming but lacks the low speed calibration for ride comfort. Another case of inability to make one unit to do it all well. Push the rising rate versions hard and they feel fine, but they do tend to ride a bit firmer than a fully coupled design.

With the Acceleration and Control Modulator (ACM) on the rising rate versions of the SC-10, Skidoo entered the coupled arena but only with rear to front one way coupling. The adjustable ACM allows the rider to control the amount of weight that is transferred to the rear arm (vary the moment of coupling through the amount of rear travel of the lower rear arm) before rate is borrowed from the front arm. The tighter the ACM is, the sooner the "coupling" occurs keeping the weight transfer at a minimum and ski pressure at a maximum. As the ACM is loosened the amount of weight transfer increases, as does the ski-lift.

The Skidoo A.C.M. is a rear to front coupler. Tightening the adjuster nut limits the rearward movement of the rear arm link, limiting weight transfer to the track. This arrangement works great for tail landings and dialing in traction or ski pressure, but does nothing for reducing the angle of incidence when the front arm hits a bump before the rear arm. There is another little link in the center of the suspension that could act as a limiter device in the rising rate versions of this suspension and possibly offer a small amount of additional coupling, but the vehicle does pitch some due to the inability to reduce the angle of incidence (keep the suspension rails parallel to the chassis) and it doesn't reach the ride quality of the true two way coupled designs.

One area that the rising rate SC-10 works so well at is the ability to accommodate a wide range of rider weights and still provide acceptable performance. From a 120 pound rider all the way to over 300 pounds simple preload adjustments are pretty much all that is needed to keep the unit working acceptably. Never before have we had such range and compliment Bombardier engineers for this ability.

The falling rate SC-10 units ride better than the rising rate designs do, all the way to the point of bottoming. Unless you are into plenty of tail landings you may prefer the ride quality of the less expensive suspensions. Too bad they don't have better shocks to go with the package.

(An interesting twist to the SC-10 rising rate suspensions with ACM is that AD Boivin has developed an add-on kit that provides full two way coupling. By attaching two composite pieces between the rails and the rear cross shaft, the fore and aft movement of the rear arm is limited via a slotted section around the cross shaft. Preliminary testing by SnowTech Magazine last season indicates that it improves the low speed ride comfort significantly at a very acceptable cost.)

The "slot" at the top of the AD Boivin ETS arms add two-way coupling to the SC-10.

Arctic Cat FasTrack:
Up until 1997, Arctic Cat was using a non-coupled rising rate suspension through their entire line. While excellent in terms of control and high speed performance the design has quite a reputation for not being the smoothest set up in town. Granted, they have been the non-conformists of the group by developing their own unique designs in the ETT angled tunnel, along with the Torque Sensing Link to control weight transfer. We were of the opinion that the TSL, while it may be a great control device did little for us in terms of ride quality. The greatest benefits will be noticed accelerating out of deep moguls where the TSL will resist compression of the rear arm and will actual keep enough weight on the skis to retain steering control. Rather than use up suspension travel during acceleration, the TSL makes the travel available when you crack the throttle.

The gold shaft in front of the rear arm link limits the forward movement of the arm, providing front to rear coupling to the FasTrack suspension. As the '97 production units arrived at the dealerships it became apparent that Arctic Cat had jumped in and decided to get some coupling into their suspension. In looking at the suspensions there was a new gold colored shaft bolted between the rails just in front of the lower section of the rear arm. While Arctic engineers insist that this is simply a reinforcing shaft they make no claim as to its function as a coupling device. There is no doubt that this will limit the amount of forward movement of this link, making it a front to rear coupler which will limit the angle of incidence and improve the ride quality. Those who owned a '97 Cat so equipped tend to agree.

Arctic Cat FasTrack Long Travel Suspension with Extra Travel Tunnel and Torque Sensing Link:
The problem with this kind of "add on design" is that it may not result in super coupling because of limits of the geometry. Just like the XTRA-10, the Arctic suspension is not a true parallelogram and thus is not afforded the range to tune the amount of coupling, as well as when to couple and when not to couple. But this still means that Arctic has no doubt moved into the coupled arena, and Arctic Cat riders all benefit from the improved ride comfort.

The Torque Sensing Link does provide many of the same results as a rear to front coupling device, especially when it comes to weight transfer characteristics. Rather than mount the rear cross shaft directly to the tunnel, it is mounted to a cantilevered arm which is in turn mounted to the tunnel. As the snowmobile accelerates, the Torque Sensing Link counteracts the tendency to compress the rear suspension by pushing down on the rear arm, which does help to maintain the rail angle parallel to the chassis. Instead of getting the skis to lift off of the ground, you can actually get the skis to stay planted during acceleration. An extra bonus is that this system also helps to maintain track tension.

FAST M-10:
Now that FAST has announced they will be building their own snowmobile, can we safely consider them an OEM? Regardless, the M-10 was the original, effective long travel and the first to introduce the whole coupling concept. In fact, all of the existing coupling designs owe their existence to what Gerard Karpik introduced on the M-10. The M-10 is a true parallelogram, allowing for full two way coupling. It is a falling rate design during the first seven inches of travel but uses a "crossover" spring which is unique to the M-10. This "spring inside a spring" is located on the rear shock inside of the larger diameter coil over spring. While enjoying the ride quality comfort of a falling rate design for the first seven inches of travel, the crossover spring is engaged for the final inches of travel which makes the suspension act like a rising rate unit with excellent resistance to bottoming.

The FAST M-10 has no rear arm "scissors" link. The equal length front and rear arms remain fairly parallel to each other by limiting the movement of the rear arm pivot. When you do bottom, the front and rear arms bottom together and the vehicle remains level with little kicking or pitching, which is true of the two way coupled systems. It is this combination of the falling rate comfort and resistance to bottoming that allows the M-10 to still, in our experience, to provide the best of both worlds - ride comfort as well as resistance to bottoming - in a wide range of operating conditions. Tail landings seem to be a strength in comparison to the other designs.

However, the M-10 is not without its drawbacks. As with other fully coupled designs weight transfer is rather limited. It requires a calibration that is weight specific, and when the rider weight varies by more than 25 pounds it is wise to make adjustments. Top speed is decreased slightly, which may not be regarded as important for the bump environments is was designed for, but is a consideration. (Top speed decreases of any more than a couple miles per hour with an M-10 are caused more by having the track tension too high than anything else.) Varying the points at which coupling occurs is not adjustable without replacing the coupler blocks. Even so, it has been the reference point of all other suspension designs for years.

The "biased coupler" limits the rear arm pivot on the M-10, providing true two-way coupling.

AD Boivin ETS Expert / Skidoo Formula Z 670 A.R.M.:

While these two suspensions are slightly different, they function basically the same. Skidoo purchased the right to further develop and manufacture the Expert suspension for use in their own machines, while allowing AD Boivin to continue to manufacture and produce their version of the suspension for aftermarket applications. It is perhaps the most radical departure in that it uses a single swing arm instead of the traditional two arms as found in all of our other rear suspensions. The suspension rails are linked directly to the tunnel with two "side-by-side" shock absorbers using dual rate springs.

The AD Boivin Expert has greater adjustability than the A.R.M. The rear black arm provides the front to rear coupling. A variable length limiter strap linkage keeps the rails parallel to the chassis during acceleration and trail landings, providing (in effect) rear to front coupling. By using a single swing arm the Expert provides a constant "wheelbase" between the ski spindle and the track which is said to provide greater stability. This should especially aid in cornering as the weight is not shifting from the front arm back to the rear arm, rather it is shifting to a single arm in varying proportions. In comparison, suspensions with two arms are constantly varying this "wheelbase" distance, constantly shifting from a short wheelbase to a long wheelbase.

This unit actually is a fully coupled suspension in that no matter which end of the suspension is compressed, the action of the suspension keeps the rails near-parallel to the tunnel at all times. Two separate mechanisms control movement of the rails on this design. The first is the rear rod or arm that attaches the rear of the rails to the rear cross mounting shaft. This rod provides the front to rear communication, limiting the angle of incidence. It could be argued that this "rod" is in reality the rear arm of our parallelogram, because without it true two way coupling does not exist.

The second mechanism, which is a very unique feature to this design, is what's called a "dynamic transfer regulator". This linkage varies the limiter strap length as the suspension moves through its travel, as well as compensating for varying rider weight or traction conditions. This in effect provides the rear to front communication. The beauty of this feature is that as the machine accelerates the limiter strap is lengthened, lowering the front of the suspension keeping as much track on the ground as possible while keeping the skis on the ground too. A second position lengthens the limiter strap which allows for greater weight transfer for those who want to use this suspension in deep snow applications.

While the Expert provides three lower mounting positions for the shocks, allowing rider selection of falling or rising rate shock speeds to suit the riding style and weight, the Skidoo version has selected a single mount. This not only reduces production costs, but removes confusion in getting the unit properly calibrated. Skidoo evidently feels that the typical buyer of the Formula Z 670 will fall into a 170-220 pound range, where the single mounting point appears to be calibrated for. The Skidoo selected mounting position appears to be slightly falling rate and accounts for the positioning of the suspension in more of a touring machine than in a cross country vehicle like an MX Z. Skidoo has struggled with dealers who were selling this suspension to riders who were better suited to an MX Z. It is not calibrated for an MX Z type rider, and likely will not perform up to the expectations of riders in those applications.

The Skidoo A.R.M. is based on the AD Boivin "Expert". The rails pivot on the single swing arm, limited by two separate mechanisms. This suspension is being used in the Formula Z 670, which is very stable and much smoother than the SC-10.

While our riding has been limited on this suspension design, it is an improvement in ride comfort compared to what Ski-Doo has offered in the past. Our experience on Formula Z 670s has been that body English is not really needed to get the machine to hook up or to corner. You can just sit back, squeeze the throttle and brake and turn the handlebars and the sled will go where you want it to. Tapping on the brakes and leaning far forward to corner is pretty much useless and really didn't seem to make much of a difference in how the vehicle handled. This is why we say it is far better suited as a cruiser than for aggressive riding.


 CHOOSING AN OIL!

Update: I have been hearing a lot of good press on Blue Marble oils = HP gains and real clean burn on the VES check it out at www.nulubes.com. Also Royal Purple just came out with a synthetic two stroke oil snow 2-C. www.royalpurple.com

Many snowmobilers still feel it necessary to use oil of their snowmobile brand name. Pull into a gas stop and the rider of one brand acts like it’s the end of the world if he doesn’t have his "brand" of oil. These same riders will use no-name brand belts, spark plugs, and other odd parts, but when it comes to oil they’ve been brain washed into thinking that their warranty is void if they don’t use that oil.

For many years this was sound advice, but it has turned into nothing more than a myth. The fact of the matter is this; you do not have to use the OEM oil to have your engine warranted. This does not mean that an oil related failure will be covered. It means there are many excellent quality oils to choose from, and that you are not obligated to use the OEM oil to keep your warranty in force. Regardless of what your dealer tells you, this is a fact.

Now, if and when engine damage does occur some dealers like to look at the oil in your tank and try to convince you this was the cause. Don’t buy it. Short of oil pump failure or oil line blockage, very, very few failures on engines operating at stock rpm levels are oil quality related.

Once you’ve made the decision that you might consider another oil, how do you know what’s fair, good, and the best? Maybe this is the reason so many stick with their name brand. They know it’s good and they’ve eliminated any guess work. After all, OEM oils are top quality and designed to keep a stock engine in good shape at standard RPM. If you add a well-designed exhaust system or optimum porting job to your engine, the horsepower will jump 20 to 30 percent, as well as the engine RPM.

The snowmobile’s oil injector pump can be adjusted to its maximum setting to increase oil volume, or put more oil in the tank premix, but this is substituting quantity where quality should be.

There are some really good motorcycle oils. Why not use those? Motorcycle engines never see the abuse snowmobile engines go through, and low temp pour point becomes a factor with motorcycle oil. When the temperature drops to zero or below, an injector pump may be waiting for oil that will never flow through the oil lines. Secondly, even if you happen to premix motorcycle oil, you may need the help of one of your friends to pull the starter rope. That’s because the oil down in the crank bearing has mutated into something closer to "road tar", the result from a -20 below zero night.

What kind of factors should you consider when choosing an oil for your snowmobile? Let’s cover a few.

Cost: This seems to be the biggie. Everyone wants a good product for a fair price. That’s called value. Why spend more than you have to, and why buy a better product than what you need ? What do you need? Does price indicate quality? Not really. It could, but don’t count on it.

Protection: This should be the paramount factor. Long term protection is what you desire, but how do you know ? If you buy the OEM brand, then you have peace of mind - you know it is good stuff. Since the snowmobile industry doesn’t have their own rating or certification method, we rely on the TC-W3 rating as used by the marine industry. A TC- W3 rating indicates at least a minimum performance standard has been met. But that standard is for outboards, not sleds. It is generally accepted that an oil with a TC-W3 certification will be good enough for the average engine in average conditions. Start cranking out horsepower and ride in below zero conditions and the need for a quality product increases. Anytime you modify the engine, add pipes, and produce more horsepower you should consider using a higher quality oil. In this case, quantity can not be a substitute for quality.

Pour point: This is one of the major factors to consider. Many outboard oils do not have very low pour points. When considering a TC-W3 oil, make sure it has a low pour point of at least -40 F. The pour point is a rating indicating the temperature the oil will no longer flow AT ALL. This means you can not use an oil all the way down to the pour point. An oil with a rated pour point of -40 should actually flow down to about -30 F. If you ride consistently in temps colder than that, you had better invest in some synthetic oil that pours down to temps even lower. A word of caution: One method of making a lower pour point is to increase the amount of "solvent" as a dilutent in the oil. This makes a lower pour point, but decreases the actual amount of oil per given amount. Our flow testing of 100% synthetic oils showed quite a difference when the mercury drops down to -40 in comparison to plain "outboard oil". Phillips Injex has turned out to be a favorite from the "multi-purpose" oils as it flows better at cold temps than what some of the synthetics did! We have consistently used Injex down to -30 F with no problems.

Availability/Mix-ability: Is the oil compatible with other brands, and how available is it? These two are tied together. By virtue of its TC-W3 designation it is compatible with any other TC-W3 rated oil. And for oils that don’t have this rating? We haven’t seen a "present day readily available oil" that causes any type of mixing problem in a long time. In fact, we went through something to the tune of over 50 gallons of snowmobile oil this past season, and intentionally poured some of EVERYTHING that we had (at one time or another) into one machine. Ran it down to -30. Seemed to work perfectly fine, but then none of it was junk lubricant, either. Non-scientific, but we know of plenty of riders who did the same. Draw your own conclusions.

Smoke & Smell: This is another of our considerations. We could have an oil with excellent protection with a rock bottom price, but if it smokes too much and stinks, we’ll find something else. That’s why we say it is hard to find a better smelling lubricant that Klotz Techniplate. The sweet smell of power? Image is everything, and your buddies will be impressed. Many of the synthetics have less smoke and smell better than what you’re using. We encourage you to buy a low smoke oil that does not stink so the non- snowmobiler’s can’t be offended. Seriously. A good place to be pro-active instead of reactive.

A recent study performed by the Southwest Research Institute compared a OEM petroleum based oil, a biodegradable synthetic oil, a semi-synthetic oil, and a isobutylene based synthetic oil. The oils were compared on a basis of the amount of oil smoke particulate matter in the emissions. The isobutylene based synthetic had 55% less smoke than the petroleum based oil, 90% less smoke than the biodegradable synthetic, and 31% less smoke than the semi-synthetic. So if you’re looking for an oil with less smoke, the isobutylene based synthetic is a proven winner.

Color: That’s right, color! Sounds stupid, but some people will buy oil (or not buy it) based on color. In reality, color now days has ZERO to do with performance. Dyes are added simply as a matter of identification, or to add color when premixed with gas. It is a matter of personal preference. We like purple or red oils better than green oil. (We like blondes better than red heads too.)

Carbon/Clean Burning: Oil experts say this can’t be pinned on oil alone, that there are several other factors that go into this. We do know when chunks of carbon flake off the top of the piston it is time to try a different oil. Or, when the exhaust power valve gets so gummed up that it doesn’t slide any longer a change would be wise. We have been most selective with our RAVE equipped Rotax engines for this reason. Even when running a 100% synthetic oil, removal and cleaning of the RAVE valves is a good idea every 1000 miles to keep them clean and free moving.

A lot of the decision goes into trust. Factor in what you hear and read, but make your own decisions based on your wants and needs. A name brand oil with a low pour point at a good price you can get your hands on will likely be just fine in your stock sled. If you are comfortable with the smell, smoke, price, availability, and do not find an excessive amount of carbon build up, you’re set. If you have increased the output of your engine above stock, protect the investment and run a higher quality oil. Do not let someone convince you to use their oil to maintain the warranty. While it is true this gives them one less factor to consider, it is not a requirement.

During the ‘97-‘98 season we ran Phillips Injex (petroleum based) in our stock sleds, Torco Synthetic (isobutylene based synthetic) in the Rotax sleds, and Klotz Techniplate (synthetic based) in our piped sleds. We’ve tried several others, some good, some not as good. We decided to use these three based on cleanliness of burning, pour points, availability, and (most importantly) protection for the application. We could have likely run other oils in any of the sleds and not "seem" to have a problem. Just like I could ride without a helmet and might not have a problem.

I wear a helmet.

 


 

NGK Spark Plugs  


So to prevent you from failing Spark Plug reading here is a multitude of counsellors in picture form.

Source NGK Spark Plugs hand out. I think their Hot-but-OK plug pictures are a bit too hot for me. But who am I to nay say NGK ?


 

1
Oil Fouled


2
Oil Fouled


3
Carbon Fouled


4
Too Cold


5
Too Cold


6
Cold or Rich
But OK


7
Cold or Rich
But OK


8
Cold or Rich
But OK


9
Good


10
Good


11
Good


12
Good


13
Real Good


14
The Best


15
Best


16
Best


17
Best


18
Good


19
Good


20
Good


21
Kinda Hot
But OK


22
Hot or Lean
But OK (?)


23
Hot or Lean
But OK (?)


24
Hot or Lean
But OK (?)


25
Too Hot or Lean
Pre-Ignition Range


26
Too Hot or Lean
Pre-Ignition Range


27
Too Hot or Lean
Pre-Ignition Range


28
Too Hot or Lean
Pre-Ignition Range


29
Too Hot or Lean
Pre-Ignition Range



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