Finally, a good site for discussion that's not product orientated. Boy am I glad I found you guys!
Ok, first off this is the first "new" sled I've owned so some of this is new to me. But in my defense I've rebuilt alot of car engines and done tuning on jet ski's so I can handle 90% of the dialect / concepts. Here goes: End of last year I bought the '96 ZRT600, it needed the typical drive clutch replacement, left rear engine mount replacement, lower left drive shaft bearing and some TLC. The sled is basically stock with very few variations. I'm having trouble with the far right cylinder fouling plugs, somewhat high oil consumption and a bog that occurs off the line and at cruising speeds below 5500rpm when you pop open the throttle. From my search I've read that the bog is fairly common with these sleds but mine is not what I would call standard in proportion. Here's the sled's specs for what its worth:
Alt. / Outside temp ridden at - under 2000' / 0-30°F
Pilot Jet - 30
Main Jet - 360
Needle Position - 3rd notch from top
Pilot Needle - 2.25 Turns out
Drive Clutch - AC # 0746-087 (stock 2001 style)
Cam Bushing - AC # 0646-016
Drive Spring - AC # 0646-147 (yellow/green)
Driven Clutch - Original AC with yellow spring and #47 Helix
Compression - On the low end of spec but within 3# variance
Resonator - Bubba's hack shop stock box, somebody cut the inside wall off and hacked away at the innards then welded a plate back on
Engine, pipes & most likely gears - Stock
Throttle position sensors - still connected (not sure how to bypass)
Questions:
1. Can I allign the clutches, if so how and can a tool be made rather than purchased?
2. Where should the oil pump marks be?
3. How do you bypass the throttle position sensors?
4. I realize that the pilot jets are on the small side should I bring them back to stock (35mm)?
5. I also realize that the mains are slightly large, but I would rather loose a little performance and gasmileage to stay away from lean burn. Should I change them too?
6. Will Bubba's hacked resonator cause a need for rejetting?
Thanks for reading my book
and trust me any info is greatly appreciated.

Ok, first off this is the first "new" sled I've owned so some of this is new to me. But in my defense I've rebuilt alot of car engines and done tuning on jet ski's so I can handle 90% of the dialect / concepts. Here goes: End of last year I bought the '96 ZRT600, it needed the typical drive clutch replacement, left rear engine mount replacement, lower left drive shaft bearing and some TLC. The sled is basically stock with very few variations. I'm having trouble with the far right cylinder fouling plugs, somewhat high oil consumption and a bog that occurs off the line and at cruising speeds below 5500rpm when you pop open the throttle. From my search I've read that the bog is fairly common with these sleds but mine is not what I would call standard in proportion. Here's the sled's specs for what its worth:
Alt. / Outside temp ridden at - under 2000' / 0-30°F
Pilot Jet - 30
Main Jet - 360
Needle Position - 3rd notch from top
Pilot Needle - 2.25 Turns out
Drive Clutch - AC # 0746-087 (stock 2001 style)
Cam Bushing - AC # 0646-016
Drive Spring - AC # 0646-147 (yellow/green)
Driven Clutch - Original AC with yellow spring and #47 Helix
Compression - On the low end of spec but within 3# variance
Resonator - Bubba's hack shop stock box, somebody cut the inside wall off and hacked away at the innards then welded a plate back on

Engine, pipes & most likely gears - Stock
Throttle position sensors - still connected (not sure how to bypass)
Questions:
1. Can I allign the clutches, if so how and can a tool be made rather than purchased?
2. Where should the oil pump marks be?
3. How do you bypass the throttle position sensors?
4. I realize that the pilot jets are on the small side should I bring them back to stock (35mm)?
5. I also realize that the mains are slightly large, but I would rather loose a little performance and gasmileage to stay away from lean burn. Should I change them too?
6. Will Bubba's hacked resonator cause a need for rejetting?
Thanks for reading my book
