The list below are notes, settings, specifications, adjustments, and modifications we use when trail converting the '08-current Polaris IQ 600R. You will need a larger gas tank, 2 pan head mounting screws, the rear supplemental heat exchanger, extra bogie wheels and a new secondary spring (160/240). We also recommend an oil injection kit and having your shocks revalved. Most recommendations on this page were based at an elevation of 0-2000ft except where noted differently. Most of the notes below originated from the 600HO conversion page.
JETTING INFO: 600HO Jetting Chart  (use a main jet that is 2-3 sizes larger than what is recommended for the 600HO)
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 except for the Needle, Jet, J8-9FH04-57 and the pilot jet.
Jetting, 420-430 mains from -10 to +30 degrees Fahrenheit 0-2000ft of elevation (some guys are using 380-440) (stock was 460 for most) starter jet 145, pilot jet 55, paj 0.7, fuel screw normally 1 turn out, the range is usually .5-1.5 turns out. If your loading up at idle turn your fuel screw in and/or try the .8 or .9 paj's
Needle Jet, J8-9FH04-57(stock) needle are running at #2 position with a 55 pilot jet or switch to a J8-9DGN06-57 (stock on 600HO)  e clip on #3 with a 35 or 40 pilot jet if your having a lean condition in the mid range.
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.
High altitude settings 8-10,000ft elevation: 250-300mains (260-270 work best) 145starter 30-35pilot with stock needle and e clip on #1 or #2. Most are using the stock needle #9FH4-57-this one is wider from the tip going up, so leaner all the way through and generally with a 45-50 pilot jet..
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.
DRIVE TRAIN 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
TSS44 Team secondary clutch-I would use the 66/44-.46 Helix with 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 (stock 600R) or 160-300.
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:
Leave it stock. Turn the timing box to G and leave it there. Run the Polaris racing oil or their VES Gold. We have also run Maxima Tundra R oil for several years now without any trouble and the exhaust valves come out clean. No matter what you do add the rear heat exchanger/cooler!
OIL INJECTION: We recommend oil injection but if you don't do it at lease do this: add oil to the cross shaft for those with a center check valve like on the '08's. Follow these instructions
Oil injection options: There are a couple of ways to do this and it depends on what year of 600R you have. The '08's are the easiest because they already  have the check valves installed in the case. On '09 and up sleds there is no oil injection check valves on the case. You can inject to the carb only or check valves can be added by drilling in the proper place(s). Instructions here
ELECTRICAL: You can rig up lights for low oil indicator, if you buy a stock oil tank with the sensor. Some lighting can be done in the stock 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 hand guards and mounts
RSI large 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-'10 600R main stock specifications plus years used***
DRIVE
Spring, Drive Clutch, Almond/Red 165/310 '05-'10
Asm., Weight/Bushing, 10-58 m '08-'10
Spring, Driven Clutch, 160/280 '07-'10
Ramp, Driven, 70/44-.46, 66/44-.46, LW '06-'10
Sprocket, 19T, 3/4W "07-'10
Sprocket, 45T '08-'10
Chain, 76P, 3/4W '08-'10
CARB
Jet, Main, Head, 460 '08-'10
Jet, Starter, #55 '08-'10
Jet, Pilot, #145 '08-'10
*** '08 600RR main specifications***
Helix Ramp, Driven 60/42-36, ER
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)
Ramp, Driven 64/42-.36    
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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