500 swap
 

Some of ya'll may know my 400.... Well it is a ported, piped, and stroked monster now. The wife said she's afraid of it. Not cause it's to fast, but cause it gets fast to fast.

So we watched a few other guys. SWT, Rich, Jbird, Kearney, and a few others who have done the 500's. So we found a 2002 polaris 500HO for 1000bucks running.

So she may not be able to race me, the wife can certainly run with me.

more

few more

some more

and more

and some more

here

almost there

That's a tight squeeze!!!!How close to having it functional are you?

Waiting on a throtle cable. It's been started so in theory just need the cable. I thought the 300 cable was the same as my koso cable ut it aint


It was very very tight. I had to do away with the rack so that left me almost 6sqft less on space just on the out side of the rack. I have 1in clearance on the new electric box location from the shock. 1in from oil tank to shock. 3in from oil tank to fuel tank. Bout an inch from fiuel tank to radiator and 1/2in from the over flow. 1in from seat to head, 2in from exhaust to battery box, 3in from muffler to radiator, and last but not least about 1in from the clutch to the shock.

It was very very tight. I aint even listing how the lines and wires run, all the tube that had to be removed and or relocated. Then the inherant issues that needed fixed that old china man did'nt mind. Like the peddles being so high from the floor a size 10 shoe could miss it.

Looking Goood Chuck!

Can't wait to see this run! Nice!

Hey Chuck i think i'm going to put the GK-13 on the trailer with the 400 and have you help me do my swap :0)

Bring it on. The 400 swap was way way easier than the 500. 2 bangers are way smaller and the 500 pipe loses power the shorter the pipe's made. So just like the 400 your cutting and reshaping a pipe so as not to change the inside diam and length.

Thanks all

Was just curious to know if an 800 mill would fit/ bolt right into a 500 frame? Sportsman is the model I'm questioning. Ever since I bought my 07 500 I've regretted not buying the 800, and you find wrecked 800's for pretty cheap
Being that I finished the install at 3am Thursday morning I didn't have the time to build a proper tunnel extension so I simply attached the snow flap to the back of the grab bar and wired it up so it wouldnt hit, well so I thought, the flap was hit constantly and got quite annoying, so a tunnel extension will be in the near future.
Also, the stock chaincase in a 1990 indy 500 is a top gear of 19 teeth, a bottom gear of 35 teeth and a chain width of 11 plates. I didn't feel comfortable with the stock gearing and trying to turn a 136" track so I purchased a 17tooth top gear and boy am I ever glad I did! I dont want the fastest sled across the lake, I just want a quick holeshot out of a corner and power to play. The only downside to changing to a 17tooth top gear was that it put a rather large dogleg in the chain in the chain case and I only have about a 1/2" of bolt left to take up anymore stretching. I will probably purchase a shorter chain for next season.

Have you tried clutching it instead of gearing it? I dont know bout sleds bro. Thats a 500 4 stroke from a quad. 12/39 gearing. My 2 stroke is geared at 13/39 But the real hole shot gains come from the stall in the drive. Just make sure your run out is within the pipes rpm

Couple short vids of the shake down

Dont think that worked

http://www.youtube.com/watch?v=HbgJl...hannel&list=UL

http://www.youtube.com/watch?v=affoa...hannel&list=UL

nice job man...awesome

Nice job!! that thing FLIES!!!!

I like it
how well does the chain/sprocket hold up?

The 50 chains are weak but a 530 is a bike chain and will last fine

good to hear, might be looking to do this to a SV :)

My SV has the real power in it. This ones my wifes. Mine has the 400 polaris and it's super nasty. If it dont make your hands shake, you need a new hobby