Caution: Please take a few minutes to read
through all of these notes. We have many hours of technical testing on
several sleds, 440 and 600HO's, to come to these recommendations. If
you still have questions that we have not answered on these pages then
feel free to call us a 319-364-1120
Many of the Polaris carb adaptors separate between the
rubber and the metal and/or crack out. See picture 1. They will suck
air and cause a lean condition and can blow your engine. Remove
the carbs and check yours. The ones we offer are the newest updated
ones and thicker than the stock ones. See picture 2. NOTE: For engine
serial #'s 0120327300140-0120327302497 replace both adaptors and if
your out of that serial number range don't think your ok-check your
adaptors.
Polaris IQ 440 carb adaptors $93.08 a pair (fits all IQ 440
models)
Polaris 600HO carb adaptors
$83.18 a pair (fits all 600HO and R's '05-'08)
440 Carb Piston valve
cutaway, 2.5$93.09ea
(aka carb slides)
These are famous for wearing down and cracking on the engine side
followed by pieces breaking off and getting sucked through you engine.
Check yours and replace them if they are cracked or warn.
IQ 440 Motor Mounts $23.26ea
Many of the motor mounts used on the '05-'07 IQ 440's
warp and are no longer centered up. If your having belt problems or
cant get the clutches to align then check yours.
600HO carb boots $15.48 a pair The carb boots that come on the 600RR and others that
many people are using on the 600HO's in the IQ racer chassis make it
very difficult to put the air box back in. We use a different set of
boots that stay in the air box and slide right on the carbs. Install
with the flush side out.
Air box info:
Make sure your air box strap is tight. You can remount the double
rivet higher up on the box or go below and double up the strap under
the lower air box bracket then double tie strap it. make sure your
bracket is not bent back allowing the air box to rub. Next trick is to
put a 1/4" rubber pad underneath the gas tank in the front to help
space it up a little and allow the air box to bee removed and
installed easier. Put your hand in the box and lift up on the carbs
while installing.
Additional info:
Many people doing 440 to 600 conversions are removing the 440 V-Force
reeds and putting them in the 600's. This is not ok unless you use the
proper stuffer. The stuffers are not sold separately and V-Force/Moto
Tassinari will not sell them separately. Example of the larger
stuffer up against the 440 stuffer in the (top picture). The proper 3
petal reed valves from V-Force are here
and come with the 100 thousands spacer kit. Although rare, some may
also need to do a case mod (bottom picture) if you are running out of
fuel at full throttle because the fuel pump cant pump enough. This
helps the pulse line fitting by grinding out a groove into the case.
This modification should only be performed by a professional.
Team secondary spacer/washer part # 11. If yours
is grooved its time for a new one.
More info here. We also
recommend the Delrin washers for your secondary spring.
Delrin Washers $10.95
Eliminates friction from spring contact with retaining cup in Team
secondary clutches
sold in a 3 pack (put 1 on each end of the spring and 1 on top of the
retainer cup)
Primary spring break?
Many the new Polaris clutches have sharp edges on the jam nuts that
are not tapered that will need to be carefully ground down with a
Dremel or air grinder. Remember, this is a balance unit so you need to
remove the same amount from all sides. If you have the tools and
access to a lathe you can taper it but you will still need to remove
any sharp edges. This will prevent the primary springs from being
scored/scratched until they break. Many of the manufactures will
warranty the first broken spring if you call them.
Skis, For trail riding I recommend the stock Polaris
snow cross ski. It has a full length carbide that is the same on
Polaris has use for 12 years now so they are easy to find. Many of the
C&A skis push snow on the keel and the start of the carbide. On
certain skis this can toss you all over the place while your riding
them. The wider Skis seem to be worse. Remember, the snow cross guys
are usually in deep artificial snow and need the lift.
click to enlarge
440/600HO oil injection pumps
Recently we have seen and heard of a few sleds that
were leaking 2 cycle oil on the ground while in storage. I strongly
recommend everyone checking the air bleeder screw on the end of the
oil injection pump on the right hand side. The last 2 brand new ones
we got in from Polaris to install were loose.
If you plug any of the pump output lines make sure this is done so
with the proper cap or plug. We are hearing of to many guys using a
screw or bolt to plug the extra oil line and the oil will still get
pushed through the threads and leak.
While your at it check to make sure the index marks are set correctly.
Adjust the cable if necessary.
Also, while were talking about 2 cycle oil leaks there are also some
people who are not running a gasket under the cap that is causing
leaks and a few others that have not run a vent tube on the oil tank.
We recommend running a vent tube down the steering loop bar on the
right hand rear side until it goes below the oil tank a few inches and
then putting in a easy bend and running it back up slightly past the
top of the oil tank and then turning the tube in a downward position
before attaching with zip ties, just snug. Be sure you don't kink the
line or over tighten the zip ties. This will allow the vent to work
but yet not leak out oil when the sled is on its side or upside down.
Oil isn't cheap so have a look and correct if necessary.
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