The list below are notes, settings, specifications, adjustments, and modifications we use when trail converting the Polaris IQ 440 to a 600HO. 600HO's will need the engine wire harness, CDI, fuel pump and all sensors. Swap mounting plates and it drops right in. You will also need new exhaust, clutch weights, springs, oil tank etc. Most recommendations on this page were based at an elevation of 0-2000ft except where noted differently.
JETTING INFO: 600HO Jetting Chart  
Before you start, pull your needle and seats out of the carbs and check in the carb inlet to insure there are not any plastic shavings from the installation of the plastic fuel fittings on the rack carbs.
Many settings are similar to the 600RR
Jetting, 400 mains from -10 to +30 degrees Fahrenheit 0-2000ft of elevation (some guys are using 380-420) (stock was 420-460) starter jet 145, pilot jet 35 (in 600RR), 40 is our favorite or 45 (most have a stock 50 pilot), paj 0.7 or 0.8 (most have stock 0.6 paj and the change makes a big difference at idle) fuel screw normally 1 turn out, the range is usually .5-1.5 turns out.
Needle Jet, J8-9DGN06-57(stock on 600HO)  e clip on #3 with a 35 or 40 pilot jet. Others are running at #2 position with a 45 or 50 pilot jet however it can create a hesitation and changing/lowering the pilot jet is the correct thing to do.
V Force 3 reeds in a 883 cage with 3 pedal carbon fiber reeds with recommended #122 stuffers and .100 spacers (V Force reeds have slightly larger than stock stuffers but cage is 3/8" shorter from top to bottom. The new cage is an 883 with 3 pedal reeds and that is what we are currently selling and the spacer kit now comes with it.
Top RPM should be 8200 to 8300 but you may still run good even at only 8000 peak RPM
High altitude settings 8-10,000ft elevation: 250-300mains 145starter 35pilot with stock needle and e clip on #1. Some are using a different needle #9FH4-57-this one is wider from the tip going up, so leaner all the way through.
Special note: Check your carb adaptors on all 440 and 600 engines. Many have separated between the rubber and metal and will leak air causing a lean condition resulting in a blown engine. Polaris actually had a recall for them on the 600HO's. Replace defectives with the upgraded ones here.
DRIVETRAIN AND GEARING: 600HO Clutching Chart Gearing Chart 1   Gearing Chart 2
Stock 600RR gearing is hyvo 22:39 and will run about 90mph in great conditions according to the radar. We are running the same gearing and hitting the same speed. The Polaris book says it should run 98 +/- a little at 8300rpm but I think the book is always about 10% high.
Primary Clutch 10-58 (10-58 could over rev a little at prolong top speed) to 10-62 weights (10-60 our current favorite) and 165-310 or 185-320 (our favorite) spring. Engagement with 10-60's and a 185-320 is 4300rpm
TSS98 Team secondary clutch with a Team Helix 66-44-42er (er for reverse) .46/.25/.25 Helix (stock 440 was a 66/44-.46) and a 140-240, 155-222 (stock RR one) or 160-240 (our favorite) spring.  If your looking for more low end, try a 160-280 or 160-300.
TSS44 Team secondary clutch-I would use the 66/44-.46 Helix with one of the springs previously mentioned.
Driven Clutch extras-On either set up I recommend 3 Delrin washers to minimize friction. (3pk is $10)
And now that I have given out all my secrets I will probably get beat at the drag races this year. Yes, I'm talking to you Brandon. All in good spirits and you'll be buying the first round.
High altitude settings 8-10,000ft elevation: Primary spring 120-340 or 120-300 or 140-300. Clutch weights 10-54 or lighter and gear to 2.05-2.15. Secondary spring 160-240 or 160-280.
SKIS and CARBIDES:
We took off the C&A skis to change to the Polaris stock snocross ski. Skis area available here. We did this to get a full length carbide and also so they are easy to find/replace at any local shop along the trail. We have used 8" and 10" carbides. The 8's steer easier but the 10's do give more control in most situations.
SUSPENSION:
Shocks have been revalved with specs from Walker Evans. Available on the suspension page (close to Pro XR set up but softer than the 600RR) The set up works awesome for a 180lbs rider. The last 3 sets we have had revalved were done by Diamond Shocks and also work great.'07 torsion springs or titanium ones are best for the rebound on the rear skid. The stock front track spring was a 160# and we put on a 140# one for a softer ride. We also did a 150#  (130# for lighter riders) for the arms instead of the stock 170#s on most models. This set up is pretty comfortable on the trail and still allows the rider to catch some air without bottoming out to bad. We also put on the 07 front limiter straps on the '05's to allow the front of the track to touch the ground and relieve a little ski pressure. On the '05's, drill out the next lower front torque arm mounting location on the tunnel and lower the arm and recheck your limiter straps. If the track is too tight remove rear idler wheel axel and take the plastic spacer blocks and grind them down in one spot where they will hit the front of rail slot. This will allow the spacer blocks to move further forward before they hit the adjuster bolts. If that doesn't solve the track tension then you may have to cut away some material from the rail to allow the rear axel to move further forward. At some point your wheels may touch the rear bumper pivot arm. If so move the arm forward to the next hole. We add 6 wheels to the suspensions to eliminate hifax wear. We recommend at least 4.
Track: We fully clip all our tracks or buy them that way and always use tall nuts on the studs with double backer plates for more stability. Our #1 favorite track is the 1.5" Camoplast Intense available here Our 2nd choice is the 1.352" Cobra here.
ENGINE:
Left it stock and plugged the lines coming off the exhaust valves-not using the solenoid. We usually remove the thermostat and reuse the grommet to seal it or put in a 440 thermostat gasket. Either method seems to work fine. We normally plug the lower coolant bypass outlet. Some guys are using the lower bypass plug and adding in an extra t fitting and running it or a different coolant bottle with 3 fittings. Rerouting the hoses to do the front cooler first from the bypass hose and then the rear cooler after the t stat is probably the best way to do it. No matter what you do add the rear heat exchanger/cooler!
ELECTRICAL: wiring diagram
Best timing seems to be 28degrees BTDC.
Its best to have the schematics or a service manual when doing any wiring. On the 600HO's in production model sleds they use a voltage regulator that produces 12vdc to run the exhaust valve solenoids and maybe some display stuff as well. The voltage regulator that comes on the production models outputs 12vac and 12vdc. The 600RR system uses a 12vdc lead coming from the stock voltage regulator.  The plug on the harness for the exhaust valve solenoid has a red/white wire and a white/yellow wire. The red/white wire is 12vdc from the converter in plug position j. The white/yellow wire goes to position e23 of the cdi plug position g. The cdi closes this to ground to open the solenoid when you start up. The solenoid is energized until you reach 6800 rpm then it closes allowing just compression pressure to open the valves. The gray wire from the purple cdi plug works the perc reverse. You can use your dragon button and put the other side/wire to ground or any brown wire. The two pin plug (black/white&white/black) use to plug into the 440 cdi for the dragon button may also need to be used for the temp light to work. My sources tell me to tie the black/white wire to the blue/white wire in position e24 from the cdi box to make the temp light work. Using the stock 440 regulator your charging coil will produce about 7-14vac. You can also rig up lights for low oil indicator, if you buy a stock oil tank with the sensor, and reverse. Some lighting can be done in the stock 440 tach but you may have to add bulbs first. Most of the indicator lights need a power wire and then the sensors or CDI will make a ground at the right time to complete the circuit and light up the light.
EXTRAS:
Skinz knee pads. These aren't just a wimpy pad. They have a thick neoprene feel to them and work great.
Gears belt cover bag. This will hold the belt and 2 maxima quick mix bottles plus some or a light fleece shirt.
We also used a Polaris handlebar bag for any extras. There are a variety of aftermarket ones available on our catalog site. Skinz also just made a low profile tank/map bag and rear tunnel paks.
WPS under hood bag
Skid plate-The Polaris Fusion will work but needs slight modification.
Polaris handguards and mounts
RSI handle bar pad
Skinz rear bumper
Cargo net
Polaris now has a quick steer/easy steer system available for $425
All the parts listed above are available form us and most are HERE

*** '08 600RR main specifications***
5136327 Helix Ramp, Driven 60/42-36, ER
7043063 SPRING-DRIVEN, CLUTCH, BLACK, LH The spring is a 155-222
Gearing is a 22-39
450 mains 145 starter and 35 pilot
*** '06 Fusion 600HO main specifications***
Primary spring black/green 120-340 w 10-62(Ok hole shot but really fast half way down the track till finish line-700ft) 5135256 Ramp, Driven 64/42-.36    7043058 Spring, Driven Clutch, Red/Black 140-240
Gearing is 23-39 after inspection (the microfiche and owners manual say two different things)
Main jet 420, starter 145, pilot 50 and paj 0.6

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