There are tons of posts on here, but nobody ever replies. Does that mean that nobody on here ever does anything with their exhaust on their sportsman?

I'm looking for something that sounds more "manly" without being super loud. Power would be nice too [img]i/expressions/face-icon-small-wink.gif[/img]

Also, what's the difference between the 500 and the 500 HO exhausts? Are the hangers actually different or is it because of flow from the higher power output?

 

I had a Big Gun exhaust on my 500. It had a nice throaty sound, but it was louder than I would have liked, but not what I considered excessive. But then my choice would be to have a less restrictive exhaust, with stock level noise output, if not lower. Noise level and your tolerance for it, is a very subjective thing. I had a non-HO and when I ordered the exhaust it indicated my year model. I had to take a hacksaw to one mounting bracket to get it to fit properly, but the bracket was aluminum and the job wasn't difficult. Other than that, it fit fine.

 

Seems as though everyone I know with a Ute ATV is looking to make them quieter rather than louder. I personally would never want to make mine any noisier then stock. I'll be leaving it alone and buying a Sport Quad if I need to Shizzle my nizzle.

 

I'm not a hunter, so I don't care about noise level. I'm used to a WR400, where I'd want to have my helmet on just to use as earmuffs if nothing else [img]i/expressions/face-icon-small-wink.gif[/img]

Here in colorado, 4WD is a necessity, and so is a low range if you're going to attempt the trickier rocks on some of the trails. That pretty much knocks out all the sport quads.

For that reason, I'm stuck making a sport quad out of a UTE. Gimmie more speed please [img]i/expressions/face-icon-small-wink.gif[/img]

 

there are plenty of systems out there, ive used the one from hot seat and liked it. deep throaty tone, but not overly loud. the ho exhaust is larger from the head back and mounts different at the muffler. yours should slip together as the ho has a donut gasket. you should be able to upgrade to the complete exhaust without to much trouble. have also used the fmf, louder and didnt like the way the discs clogged with mud on the boggers.
speaking of not posting, ive replied to afew of your posts without a response back. like did you get the u-joint you were asking about earlier?

 

Thumper33,
Do you have a non-H.O. or H.O.?


Pro Circuit makes a full system for the Sportsman 500 that will fit both H.O. and non-H.O. models. It's $474.95 (including shipping) in Dennis Kirk (www.denniskirk.com). If you find it cheaper anywhere else Dennis Kirk will beat any catalog price by $1. I'd take a good look at that one.

 

sorry jeffro... I didn't mean to be ungrateful. You've been the savior to almost all my problems lately [img]i/expressions/face-icon-small-happy.gif[/img]

I just have so much going on lately that I can't stay on one task [img]i/expressions/face-icon-small-wink.gif[/img] Call it ADD I dunno.

I did get the part number for the u joint. I think that would be the right one!!! How did you get that part number? The Polaris dealer sent me away and told me to let them know when I figured it out. [img]i/expressions/face-icon-small-shocked.gif[/img]

Anyway...


I have a 96 non-HO, but I've got a 2002 HO motor at Four Stroke Tech now being stoked out to a 600 [img]i/expressions/face-icon-small-happy.gif[/img]. I'm sure it'll want a better exhaust system then the stock non-HO, so that's why I'm looking.

 

Hey! I was wondering about FST 600 kit for the Polaris 500 motor. If you don't mind telling me..what did they quote you for a price?

 

i know you're not being "ungrateful", didnt mean to imply that i thought you were. know what you mean about all the projects, right now trying to finish raptor for xc, 250ex rebuild, intruder 1400 w/ major motor problem, etc, etc,[img]i/expressions/face-icon-small-confused.gif[/img][img]i/expressions/face-icon-small-wink.gif[/img]

for the part numbers log on to polarisindustries.com, worldofpowersports.com, or many others. on polaris site make sure to look at your 96, not the norwegian model. there are some differences.
since fst is doing the mods, check with micky or one of the guys, maybe they have a system or recommendation that works with it.

 

FYI on the FST kit - I have a spare engine, so I'm sending that in and letting them set everything up. I can't recall exact numbers, but here's a close estimate.

600 stroker kit including new h/c piston and all - $575
long duration cam - $240 I think and that included valve springs. That's modding the cam you have.
Cylinder bore - $45
Port/flow on the head - $200ish.

I'm sorry I can't find my notes right now so this is off the top of my head. I remember them saying $150 if I just wanted to put a HO cam in instead of a long duration cam. The only difference in the price of the cam is that the long duration requires new valve springs (add $90)

It ended up for me since I'm having them do the assembly and valvework at about $1035 w/o the long duration cam and port/flow, or about $1325 with long duration cam and port/flow.

He did say it'd take about a month from the time I sent him the engine until I could expect to see it back. Again, not such a big deal since it's a spare engine at this point.

I'm going to take it to a local shop after I get the engine installed to have them set up jetting for me. I has someone recommend extreme-performance for high-altitude tuning, and they're about 15 mins from me. [img]i/expressions/face-icon-small-smile.gif[/img] I guess they have dynos that they use to tune it. My understanding is that this is the right way to do it. I'm anxious to see what the curves look like on a 600 stroker. By the sounds of it, FST doesn't need any more business, but I'll be sure to do a writeup all about it once I'm done. The engine is on it's way there now, so look for more info in about 6 to 8 weeks. I'll definitely post here when it's done too. Feel free to email me if you have any other questions. I'm not an expert yet, but I spend a couple hours a day researching, so I'm getting there [img]i/expressions/face-icon-small-wink.gif[/img] my email address is mnevitt@offroadtoystore.com