2009 MX Zx 600 RS Key Features and Improvements. Powertrain Rotax® 600RS engine NEW dual air intake system NEW tuned pipe support Runs on 98E octane fuel. 2009 MX Zx 600 RS Key Features and Improvements. Suspension – NEW Calibration Front and Rear SC-5 rear suspension
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Pipe Heat Function
2009 Rev-XP 600RSCarburetor Synchronization&TPS adjustment procedure
Ref pg 47
The check engine light will appear when the TPS adjustment is complete.
Release the throttle lever and the “Holeshot” button.
Disconnect the battery and the supply harness.
Put back the diagnostic port in its connector on the vehicle.
Understanding basics, crucial for tuning
Lightweight TRA III Drive Clutch
Team Performance LW Driven clutch
Controls Engagement RPM well as shift RPM
Ref pg 139
Ref pg 129
1-2 .698 deg .014
2-3 1.062 deg .031
3-4 1.245 deg .032
4-5 1.225 deg .027
5-6 .540 deg .018
Total 4.770 deg .122
Ref pg 169
Ref pg 164
Ref pg 168
3mm End Play
Add 1-1mm shim
2mm Total End Play
Ref pg 187
Part # 529 036 122
Ref pg 197
Ref pg 99
SC-5 Rear Suspension
For sno-X application install front shock piggy back toward the frame. The remote reservoir must face forward of the vehicle. If not installed properly interference may occur and major damage is possible.
Ref pg 117
Raise the front of the sled until the skis are off the ground.
Measure from carbide to carbide at the front and repeat at the rear.
Adjust BOTH tie rods until you achieve 1/8” toe out. (A 1/8” longer than B)
4 position rear coupling block
5 positions rear torsion spring adjuster
On hard icy tracks, wheels may be used. Install them on the outside part of the rail.
When installing the rear torsion springs, place the holding block in the UP position.
In the HPG shock, the piston passages are covered by a stack of thin metal shims of various thicknesses and diameters. The shims provide dampening by acting as spring loaded valves offering resistance to the oil traveling through the piston.
NOTE: For the new 2009 C-40 shocks, always use 34 mm diameter shims against the piston for compression dampening and 30 mm diameter shims against the piston for rebound dampening.
Please refer to your racing handbook pages 57-60 for more information.Shock basic understanding
The diameter of the smaller shims that support the large shims will also affect the dampening. A larger support shim gives more support to the large shim thus making it act stiffer.Shock basic understanding
Another method of changing dampening is by controlling the amount of space the stack has to open. This is done by reducing the amount of smaller shims which support the larger shims. The larger shims act the same until they bottom out against the valve stopper.Shock basic understanding
Low Speed Compression Adjuster amount of space the stack has to open. This is done by reducing the amount of smaller shims which support the larger shims. The larger shims act the same until they bottom out against the valve stopper.
The low speed adjustment is used to change the dampening force for relatively slow suspension movement. It is used to tune the vehicle for braking, cornering, holeshots and all the bumps that create low speed movement in the suspension. The low speed adjuster has 4 turns of adjustment. Turning the adjuster clockwise increases the dampening.
High Speed Compression Adjuster
The high speed adjustment is used to change the dampening force for fast suspension. It is used to tune the vehicle for large, high speed jumps and bumps that create high speed movement in the suspension. The high speed adjuster has three turns of adjustment. Turning the adjuster clockwise increases the dampening.Shock clickers
1. Tightly secure the shock base in vise. DO NOT
CLAMP ONTO SHOCK BODY.
2. Using a 12mm wrench, slowly remove air inlet
valve, allowing the gas inside the reservoir to
3. Remove top shock cover using a 36 mm
wrench. Pull shock rod out of main shock
4. Dispose of used oil properly.
5. Push down the remote reservoir cover to remove
the retaining circlip.
6. Remove the remote reservoir cover.
7. Remove the floating piston inside the remote reservoir.
8. Remove lock nut using a 19 mm wrench securing valve stack and piston to rod.
9. Carefully remove and layout shims, washers and piston from rod. Play close attention to shims and washers sequence and piston position.
10. Clean all shock components using pulley flange cleaner (P/N 413 711 809). DO NOT MIX SHIMS AND WASHERS TOGETHER.
11. Assemble valve shims, washers and piston in proper order and place them back onto shock rod.
12. Torque the rod nut at 45 N•m (33 lbf•ft).
13. Fill main shock body with shock oil (P/N 293 600 035) to a level of half full.
14. Fill remote reservoir with shock oil to within 6.4 mm (1/4 in) from the top.
15. Hold the remote reservoir in a way so the oil level in it at the same height of the level in the shock.
16. Cup your hand and place it over the remote reservoir. Pump with your hand to circulate oil through the base valve (adjustment system) to remove any trapped air. Low speed adjuster must be open 1 turn minimum.
17. Fill the remote reservoir with oil. Lubricate O-ring seal on floating piston with shock oil and install. The key to good shock performance is to remove all the air from shock body reservoir and valve stack.
18. Push the floating piston to the bottom of the remote reservoir. Oil will rise in the main shock body almost to the top.
19. Fill the shock body with oil until level with bottom of threads.
20. Lubricate seal around piston and valve stack and gently push into main shock body.
21. Stroke the piston and valve stack slowly to remove any trapped air. Using a small hammer or wrench, gently tap on the rodmounting eyelet to help remove air.
22. Again, push the floating piston to the bottom of the remote reservoir.
23. Pull the shock shaft as far out as possible and replace the seal cover and torque to 65 N•m (48 lbf•ft). Oil must spill from the shock body before the seal cover O-ring seals the shock.
24. Install the remote reservoir cover. Install the retaining clip. Pull cover to seat against the retaining clip. Make sure the cover is firmly seated against the retaining clip before filling with gas.
25. Install the air inlet valve.
26. Pressurize the shock at 2070 kPa (300 PSI) with nitrogen (N). Use the correct gas fill tool kit (P/N 503 190 102).