2004 Polaris ProX 800 tuneup
Transcription
2004 Polaris ProX 800 tuneup
2004 Polaris ProX 800 tuneup This particular ProX800 is owned by Dave Mitchell (AKA Shylock44), a good pal of Tim Bender who was anxious to perk up the performance of his sled. Sean Ray had the opportunity to dyno tweak and tune his Dad’s XC800 last year. At close to 150 HP it ran 100 ¼ mile asphalt runs (mid tens) on 93 octane pump gas with no problem, and has proven similarly reliable on the lakes and trails this winter. Sean was eager to try the same setup on the ProX. The ProX engine now has a detonation sensor that causes the ECU to retard timing when it detects knock. If it works, this should be a great benefit for performance sledders whose greatest challenge is usually achieving the greatest HP for the longest WOT time on the lowest octane gas. We suspected that it was the deto sensor that gave us fits when certifying the ProX800 for the AmSnow Shootout. There may have been some slight high frequency vibration from the dyno that “sounded” like deto to the ECU. Since then I have added additional elastic media to the dyno shaft system to further protect engines from their own torsional vibrations. This may be the reason that this ProX engine ran flawlessly on the dyno for two days while we did this step by step tuneup. Here is the baseline test data on a 35 degree F day, obviously much better than our Shootout sled fared in similar atmospheric conditions. test c, 04 ProX800, stock baseline, stock 450 main jets EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 6200 77.4 91.4 0.78 72.2 10.9 6300 77.5 92.9 0.77 72.1 11.1 6400 78.9 96.2 0.77 74.5 10.7 6500 81.1 100.3 0.78 78.5 10.3 6600 82.8 104.1 0.76 80.1 10.5 6700 82.5 105.3 0.76 80.2 10.6 6800 82.6 107.1 0.77 83.5 10.5 6900 82.9 108.9 0.83 91.2 9.7 7000 83.6 111.4 0.85 94.9 9.4 7100 84.7 114.4 0.93 106.7 8.6 7200 83.3 114.2 0.91 103.1 8.9 7300 83.1 115.5 0.87 100.6 9.2 AirTmp degF 172 174 175 177 183 186 192 194 195 200 201 202 AirDen lb/cft 35 0.079 35 0.079 35 0.079 35 0.079 35 0.079 35 0.079 35 0.079 36 0.079 36 0.079 36 0.079 36 0.079 36 0.079 7400 7500 7600 7700 7800 7900 8000 83.4 89.6 88.5 87.4 86.1 85.8 77.8 117.5 128.1 128.1 128.2 127.9 129.1 118.5 0.82 0.74 0.72 0.65 0.73 0.84 0.89 97.3 95.7 93.5 84.3 93.6 109.2 107.1 9.6 10.1 10.5 11.6 10.6 9.1 9.3 203 211 214 214 217 217 218 36 36 36 36 35 36 34 0.079 0.079 0.079 0.079 0.079 0.079 0.079 Sean then removed the 450 main jets and installed 410s to lean out the engine about 10% (Mikuni hex main jet numbers are approximately proportional to fuel flow). This raised the power peak a bit due to the hotter exhaust gas (ProX owners have reported that the stock pipe needs to be smoking hot for best performance). The float bowls are properly vented to the airbox, but below the shelf. For reference, we measured airbox restriction and saw 9” of negative water pressure in the airbox at the venturi inlets and inside the float bowls. test f, 04 ProX800, jet down to 410 mains EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 6200 77.8 91.9 0.71 65.6 12.1 6300 78.4 94.1 0.77 73.1 10.9 6400 79.6 97.1 0.73 71.2 11.4 6500 82.2 101.7 0.71 71.6 11.5 6600 82.7 103.9 0.68 71.2 11.9 6700 84.4 107.6 0.71 75.4 11.4 6800 85.8 111.2 0.68 76.6 11.4 6900 87.8 115.4 0.68 79.5 11.4 7000 88.4 117.9 0.68 80.3 11.3 7100 87.7 118.6 0.69 82.2 11.1 7200 88.4 121.2 0.67 81.5 11.5 7300 88.7 123.3 0.71 86.8 10.9 7400 89.1 125.6 0.82 103.9 9.3 7500 88.7 126.7 0.78 99.9 9.7 7600 89.2 129.1 0.74 96.9 10.2 7700 89.9 131.8 0.68 90.2 11.1 7800 89.9 133.5 0.59 79.4 12.6 7900 90.1 135.4 0.73 99.8 10.1 8000 85.1 129.7 0.75 97.8 10.3 8100 52.2 80.5 1.18 95.8 9.9 AirTmp degF 174 174 177 180 185 188 191 198 199 199 205 206 210 212 215 217 218 221 220 207 AirDen lb/cft 34 0.079 35 0.079 35 0.079 35 0.079 36 0.079 36 0.079 36 0.079 36 0.079 36 0.079 36 0.079 35 0.079 35 0.079 35 0.079 35 0.079 35 0.079 37 0.078 37 0.078 36 0.079 36 0.079 36 0.079 Next, we removed the shelf from the airbox. This had a dramatic effect on airflow CFM, but it also enrichened the A/F ratio (the opposite of what we might expect if the float bowls were originally vented above the shelf). test h, 04 ProX800, remove shelf from inside airbox EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 6200 78.3 92.4 0.71 65.2 12.9 6300 78.9 94.6 0.69 65.9 12.8 6400 81.5 99.3 0.72 71.5 12.1 6500 82.4 101.9 0.69 70.6 12.5 6600 84.9 106.6 0.68 72.8 12.4 6700 85.8 109.5 0.68 75.4 12.2 6800 87.7 113.6 0.67 76.6 12.2 6900 89.7 117.9 0.67 79.3 12.1 7000 90.8 121.1 0.69 84.1 11.6 7100 89.5 120.9 0.69 84.1 11.7 7200 89.5 122.6 0.68 83.8 11.8 7300 92.9 129.2 0.66 86.3 11.7 7400 92.2 130.1 0.66 86.2 11.8 7500 91.5 130.7 0.77 101.5 10.2 7600 91.9 133.1 0.74 98.7 10.6 7700 91.9 134.8 0.76 103.6 10.1 7800 93.2 138.5 0.69 95.9 11.1 7900 91.1 137.1 0.73 100.6 10.6 8000 84.7 128.9 0.78 101.4 10.6 AirTmp degF 184 185 189 192 197 200 204 209 212 215 215 220 223 225 228 230 232 233 235 AirDen lb/cft 36 0.079 36 0.079 36 0.079 36 0.079 36 0.079 36 0.079 36 0.079 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 37 0.078 32 0.079 Since jetting was still too conservative for us, especially in light of the deto sensor that ultimately needed to be tested, we dropped to 390 mains which gave us low .60’s BSFC in 35-40 degreeF air in the dyno room (use Mikuni Slide rule to correlated this 92 octane spec to other conditions). test I, 04 ProX800, jet down again to 390 mj EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 6200 78.1 92.2 0.71 64.4 13.1 6300 78.9 94.7 0.68 64.7 12.9 6400 80.9 98.6 0.68 67.7 12.5 6500 83.4 103.2 0.71 72.5 12.1 6600 84.2 105.8 0.71 74.5 11.9 6700 86.1 109.8 0.68 74.8 12.2 6800 87.4 113.1 0.68 77.7 11.9 6900 91.2 119.8 0.65 78.2 12.2 7000 90.9 121.1 0.66 79.7 12.1 7100 90.6 122.4 0.66 81.1 12.1 7200 91.4 125.2 0.67 84.2 11.7 7300 92.9 129.2 0.63 81.7 12.2 AirTmp degF 183 182 185 190 194 199 202 208 209 212 215 218 AirDen lb/cft 38 0.078 38 0.078 38 0.078 37 0.078 37 0.078 38 0.078 39 0.078 39 0.078 39 0.078 39 0.078 39 0.078 39 0.078 7400 7500 7600 7700 7800 7900 8000 8100 93.3 94.8 94.3 96.1 95.8 95.5 93.5 85.2 131.5 135.4 136.5 141.1 142.3 143.6 142.4 131.5 0.63 0.72 0.66 0.63 0.63 0.61 0.63 0.65 82.5 98.1 90.5 89.1 89.9 88.2 89.8 85.6 12.2 10.4 11.4 11.8 11.8 12.1 11.9 12.5 219 223 225 229 231 232 234 233 40 40 40 40 39 39 39 38 0.078 0.078 0.078 0.078 0.078 0.078 0.078 0.078 Sean next installed a set of Vforce 3 reeds that had the plastic inserts matching the oval stock carb boots. Though Sean had seen about 1 HP from these reeds on his Dad's XC800, we were disappointed to see the reeds have insignificant effect on airflow and HP on this engine with the stock pipe in place. We would leave the Vforce reeds in for now. test L, 04 ProX800, install Vforce 3 reeds EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 6200 76.7 90.5 0.66 60.6 13.6 6300 77.6 93.1 0.64 60.5 13.7 6400 81.1 98.7 0.66 65.2 13.1 6500 80.4 99.5 0.67 66.7 12.9 6600 83.9 105.4 0.65 68.7 12.9 6700 83.9 107.1 0.65 69.7 12.9 6800 86.6 112.1 0.67 75.2 12.3 6900 86.6 113.7 0.64 73.8 12.6 7000 87.7 116.8 0.63 74.4 12.7 7100 89.1 120.4 0.63 77.1 12.5 7200 88.6 121.4 0.64 78.7 12.3 7300 92.1 127.9 0.67 86.9 11.4 7400 92.2 129.9 0.63 83.1 12.1 7500 93.7 133.8 0.71 96.2 10.6 7600 93.1 134.6 0.61 81.3 12.6 7700 93.4 137.1 0.62 85.2 12.1 7800 95.1 141.2 0.66 94.4 11.1 7900 95.1 143.1 0.64 92.7 11.5 8000 94.5 143.9 0.59 85.5 12.5 8100 93.1 143.4 0.62 89.7 11.9 8200 59.4 92.8 0.91 85.1 11.9 AirTmp degF 180 181 187 188 193 196 202 204 206 210 211 216 219 222 224 225 228 232 234 233 222 AirDen lb/cft 35 0.079 35 0.079 35 0.079 35 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 34 0.079 35 0.079 33 0.079 33 0.079 34 0.079 33 0.079 Changing the static ignition timing in the ProX requires lifting the engine out of the sled to gain access to the flywheel area. I said: “Sean are you sure you want to spend an hour of F’ing around to add about one more HP?” Sean said “Yup” [that’s one reason Tim Bender hires Sean to be sort of a Team Industries/ Polaris “sled chief” at major snow-cross events when Sean has time to help out] . We removed the dyno shaft, removed motor mounts etc and jacked the engine up above the bulkhead. After pulling the flywheel, Sean was able to move the stator plate (with slotted attaching holes) @1/8” counter clockwise, all the way to the stops. After reinstalling the engine we were rewarded with extra torque and HP throughout the powerband. Time well spent. test O, 04 ProX800, advance timing by rolling stator 1/8" to the stops EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 AirTmp RPM Clb-ft CHp lb/hph lb/hr Ratio scfm degF 6200 78.1 92.2 0.71 65.4 12.4 178 6300 79.6 95.5 0.69 66.3 12.4 179 6400 81.3 99.1 0.69 68.6 12.1 182 6500 82.6 102.2 0.68 70.7 12.1 186 6600 85.6 107.6 0.66 72.2 12.1 190 6700 86.7 110.6 0.66 73.5 12.1 193 6800 89.4 115.7 0.64 75.1 12.1 199 6900 90.1 118.2 0.63 75.8 12.2 201 7000 92.4 123.2 0.62 76.7 12.3 207 7100 93.3 126.2 0.62 79.2 12.1 208 7200 94.8 129.9 0.62 81.6 11.9 212 7300 96.2 133.7 0.63 85.2 11.5 214 7400 97.3 137.1 0.64 88.3 11.3 219 7500 97.2 138.9 0.65 90.8 11.1 220 7600 97.9 141.6 0.53 76.3 13.3 222 7700 98.8 144.8 0.61 88.4 11.6 225 7800 98.1 145.7 0.64 93.7 11.1 228 7900 96.4 145.1 0.62 91.5 11.5 230 8000 92.1 140.4 0.71 99.7 10.6 231 AirDen lb/cft 34 0.079 34 0.079 33 0.079 32 0.079 32 0.079 32 0.079 33 0.079 32 0.079 31 0.079 32 0.079 32 0.079 32 0.079 30 0.08 31 0.079 32 0.079 33 0.079 33 0.079 32 0.079 33 0.079 We had ordered aftermarket single pipes from several sources, but after a month of waiting only the silver ceramic coated Starting Line Products pipe/ can combo was available. While we were at first disappointed that the pipe would not fit the stock quiet muffler, we were pleased that the SLP muffler was very quiet, only a few dB louder than stock. Note that the SLP single added five lb/ft of torque and over six HP while adding significant airflow CFM to the engine. test R, 04 ProX800, install SLP single pipe, Ypipe and muffler EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 6100 77.8 90.4 0.74 67.8 11.9 6200 77.2 91.1 0.73 66.9 12.1 6300 78.1 93.7 0.72 67.9 11.9 6400 82.3 100.2 0.69 70.1 12.1 6500 84.5 104.6 0.68 72.1 12.1 6600 85.8 107.9 0.65 71.1 12.5 6700 88.2 112.5 0.64 73.2 12.4 6800 92.1 119.2 0.64 76.5 12.2 6900 95.4 125.4 0.63 80.2 12.1 7000 97.8 130.4 0.62 81.2 12.2 7100 98.9 133.7 0.62 84.1 12.1 7200 99.9 136.9 0.62 85.6 12.1 7300 101.3 140.8 0.61 85.1 12.4 7400 101.1 142.4 0.64 92.6 11.4 7500 102.7 146.6 0.64 94.5 11.4 7600 102.7 148.5 0.65 96.8 11.2 7700 103.8 152.2 0.59 91.3 12.1 7800 102.6 152.3 0.64 98.3 11.3 7900 99.7 150.1 0.64 97.2 11.4 8000 88.7 135.1 0.69 94.5 11.6 AirTmp degF 176 176 177 184 191 194 199 205 212 217 221 224 230 232 235 238 240 243 243 239 AirDen lb/cft 33 0.079 33 0.079 33 0.079 32 0.079 32 0.079 32 0.079 32 0.079 32 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 34 0.079 34 0.079 34 0.079 A late arrival was a new set of Boyeson Rad Valve reed cages which we installed. Though airflow showed a slight increase at peak compared to VForce, there was no change in HP, even though fuel flow remained relatively constant. We first saw this happen in 1991 when Tim Bender dyno’d the original (then secret) Vmax4 FIII “crate” race engine he received from Yamaha. The first thing Tim tried (of course he couldn’t leave it alone even though it was about 50HP stronger than his old Exciter FIII’s) was a set of reed cages with larger reed windows, designed for a Yamaha 250 motocross bike. Airflow CFM went up, HP went down. ???. So the logical thing was to try four stock Phazer reed cages which had even smaller reed windows. Airflow CFM went down a few percent, HP went up a few percent so that’s what Tim used. The rule is, HP rules. In this case, HP is virtually identical—repeating within a few tenths of HP. test 1b, 04 ProX800, remove Vforce reeds, install Boyeson Rad Valves EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 AirTmp RPM Clb-ft CHp lb/hph lb/hr Ratio scfm degF 5700 71.1 77.2 0.75 58.8 12.4 160 5800 71.7 79.1 0.81 64.8 11.4 162 5900 73.1 82.1 0.79 65.6 11.5 164 6000 73.5 84.1 0.79 67.4 11.4 168 AirDen lb/cft 26 0.08 27 0.08 27 0.08 27 0.08 6100 6200 6300 6400 6500 6600 6700 6800 6900 7000 7100 7200 7300 7400 7500 7600 7700 7800 7900 74.3 77.2 79.4 82.6 84.4 88.6 90.7 91.1 95.2 98.1 99.1 99.8 101.6 102.9 103.6 104.9 103.8 102.5 98.8 86.3 91.1 95.2 100.7 104.4 111.4 115.7 117.9 125.1 130.6 133.9 136.8 141.2 144.9 147.9 151.8 152.1 152.2 148.7 0.76 0.74 0.75 0.72 0.72 0.73 0.71 0.71 0.68 0.68 0.71 0.68 0.67 0.67 0.62 0.62 0.63 0.61 0.64 66.2 68.9 72.4 73.4 76.1 82.6 83.6 84.2 86.1 90.2 95.3 95.2 96.1 98.1 92.7 95.1 97.2 93.4 97.1 11.7 11.5 11.3 11.6 11.5 11.3 11.3 11.4 11.5 11.5 11.1 11.2 11.3 11.3 12.1 11.9 11.8 12.3 11.9 169 174 179 187 191 203 206 209 216 227 231 233 238 241 244 247 250 250 252 27 26 26 26 26 25 25 25 25 25 24 25 25 25 26 27 26 26 26 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 Next, we reinstalled the stock reed cages. This time we saw a very slight airflow decrease and a very slight, not significant decrease in top end HP if you look at the overall numbers there. This could only be measured on a dyno. So probably because of the higher airflow of the SLP exhaust, there was some gain from the aftermarket reeds, maybe ½ HP average at the crest of the power curve. Dave opted to stay with the stock reeds. test 1d, 04 ProX 800, remove Boyeson Rad Valves, reinstall stock OEM reed cages EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 AirTmp AirDen RPM Clb-ft CHp lb/hph lb/hr Ratio scfm degF lb/cft 5700 71.9 78.1 0.74 67.8 11.9 157 30 0.079 5800 72.1 79.5 0.73 66.9 12.1 158 31 0.079 5900 73.1 82.1 0.72 67.9 11.9 161 31 0.079 6000 73.3 83.7 0.69 70.1 12.1 163 31 0.079 6100 75.3 87.4 0.68 72.1 12.1 168 30 0.079 6200 76.1 89.7 0.65 71.1 12.5 170 29 0.08 6300 80.2 96.2 0.64 73.2 12.4 178 29 0.08 6400 82.6 100.6 0.64 76.5 12.2 183 29 0.08 6500 85.9 106.3 0.63 80.2 12.1 190 29 0.08 6600 89.1 112.1 0.62 81.2 12.2 200 30 0.079 6700 90.6 115.5 0.62 84.1 12.1 206 30 0.079 6800 93.2 120.7 0.62 85.6 12.1 209 31 0.079 6900 97.1 127.6 0.59 85.1 12.4 220 31 0.079 7000 98.1 130.6 0.64 92.6 11.4 222 31 0.079 7100 100.1 135.3 0.64 94.5 11.4 228 30 0.079 7200 7300 7400 7500 7600 7700 7800 7900 100.4 101.6 103.8 102.8 103.6 103.9 101.8 98.3 137.6 141.2 146.3 146.9 149.9 152.3 151.2 147.8 0.65 0.6 0.64 0.64 0.69 0.71 0.62 0.76 96.8 91.4 98.3 97.2 94.5 108.3 95.6 113.7 11.2 12.1 11.3 11.4 11.6 10.4 11.9 10.1 230 233 238 239 244 245 248 248 30 31 31 31 30 30 30 30 0.079 0.079 0.079 0.079 0.079 0.079 0.079 0.079 The final change was to lower compression one full point from 12.5 to 11.51 uncorrected. Sean’s idea is that the stock compression is high for a pump gas engine that’s tuned the way we like them. Plus since his dad is old like me, pull starting was a challenge especially when Tug Hill Temps drop well below zero. Sean first tried the reduced compression concept on his Dad’s XC800, and was able to match the original compression HP with added timing. He left the squish band stock, and CNC machined the bowls to add the necessary volume. In this case, the much lower compression only dropped one HP at peak. Sean’s idea is that the higher compression HP could be restored with one or two more degrees of timing (in this case requiring grinding out the slots in the stator). We’re thinking that the same HP with added timing with lower compression could ultimately result in lower peak cylinder temp (= less chance of deto). Here’s one full point lower compression than stock with identical timing. test 1k, 04 ProX800, reduce compression one point EngSpd STPTrq STPPwr BSFC Fuel A A/F Air 2 RPM Clb-ft CHp lb/hph lb/hr Ratio scfm 5700 71.3 77.3 0.75 58.7 12 5800 71.3 78.7 0.77 60.8 11.8 5900 72.1 80.8 0.78 63.3 11.4 6000 73.5 84.1 0.78 65.7 11.3 6100 74.8 86.9 0.75 65.6 11.5 6200 76.6 90.4 0.74 67.2 11.5 6300 77.9 93.5 0.72 68.1 11.6 6400 80.8 98.4 0.72 71.3 11.5 6500 83.6 103.4 0.71 73.8 11.5 6600 87.1 109.5 0.69 76.3 11.6 6700 89.7 114.5 0.71 82.3 11.2 6800 92.1 119.3 0.69 83.1 11.4 6900 94.1 123.6 0.69 86.2 11.4 7000 96.1 128.1 0.69 89.5 11.2 7100 96.3 130.2 0.67 88.3 11.5 7200 97.1 132.9 0.68 91.6 11.3 7300 98.1 136.3 0.67 91.9 11.3 AirTmp degF 154 156 158 162 165 169 173 179 185 193 201 208 214 219 223 226 228 AirDen lb/cft 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 33 0.079 32 0.079 32 0.079 33 0.079 32 0.079 32 0.079 33 0.079 33 0.079 34 0.079 7400 7500 7600 7700 7800 7900 8000 101.1 101.7 102.1 102.9 101.9 98.4 93.2 142.4 145.2 147.7 150.8 151.3 147.9 142.1 0.66 0.64 0.63 0.59 0.58 0.58 0.68 95.1 93.4 94.1 90.1 88.7 86.3 97.4 11.3 11.6 11.7 12.4 12.7 13.1 11.6 234 237 240 243 245 248 247 34 34 34 35 35 33 34 0.079 0.079 0.079 0.079 0.079 0.079 0.079 EPILOGUE The perplexing thing about this ProX800 sled is that if the detonation sensor works and the ECU protects, why would Polaris provide stock carb calibration at 10/1 A/F ratio at close to .80 lb/hphr? I shouldn’t complain because that sort of lazy calibration provides job security at DynoTechResearch. But guys like Dave Mitchell who’s not a savvy engine tuner bought this sled for performance riding. Because of this ultraconservative stock setup Dave has been at the back of the pack all season, but no more thanks to this tuneup and Sean’s clutch setup. Please note that in some of this test data the fuel flow is not as smooth as it could be, probably due to some engine harmonics aggravated by the dyno. So we have to mentally average out fuel flow spikes that have no effect on overall actual combustion chamber A/F ratio. The dyno measures fuel as it goes into the sled’s fuel pump, and these small spikes have very momentary effect on float bowl level and have little effect on what fuel actually travels up the needle jets into the engine.
Similar documents
2012 American Snowmobiler/DTR NY Shootout dyno certification, etc.
preproduction 07 Jag Z1 made 132hp at 8900rpm just below the rev limit. Last year, we thought that the F1100 shootout sled was “stuck” in reverse mode, limiting peak revs to 5800, and making a flat...
More information