I have a '99 Magnum 500 that I would like to upgrade. I have done the Highlifter kit (jets, filter, and a Supertrapp that keeps breaking at the headpipe)but still want more power. Has anyone done the H.O. upgrade (cam, 40mm carb) to one of these? Also, I would like to change to an Aaen roller clutch. Any problems with that particular piece? I know I asked a lot of questions, but I would appreciate any input. This is my first post, and I will be a regular to help when I can. Thanks in advance.

 

I can't find their web site either, but I did call and get a catalog last year. There is an e-mail address on it: aaenperf@wi.net. Maybe this will help.

 

TH,
You said that you have the 99, so I'm thinking you have the EBS system???... Does AAEN now make the roller secondary for the EBS system?.. I know that Hot Seat Performance does.....
As for internal mods, you can get everything you need to H.O. your magnum for about $350.00...
Camshaft, 40mm Carburetor with necessary linkage, gaskets, carburetor intake boot...
Good Luck

 

I am not sure if the Aaen roller clutch works with EBS. The catalog I have does not specify. I'll check it out, and I will also check out Hot Seat's version. Did you upgrade your Mag? I was wondering how much of a difference it really makes. Thanks for the help.

 

Thumper, Here is what I have done to date:


1)26" Mud Runners with coil spring spacers (keeps tires from hitting plastic after hitting hard bumps)
2)K&N air filter
3)Replaced cam with new one from polaris. Not the scrambler cam but is a superceded number that measured .008" more lift than original.
4)Wiseco piston. (Rings never seated on original)don't know why. Experienced abnormal oil consumption. Wiseco piston pin is much lighter than original, which helps in letting engine rev a little quicker.
5)Increased main jet to 160
6)Replaced final drive gears in gearcase with the lower geared version from the Magnum 325.
7)Replaced the EBS with stock non EBS PVT system.
8)And the rest all cosmetic: heated hand grips, hand guards, front and rear rack extenders, front and rear double tube bumpers, Warn 2000 lb winch, Front and rear camo rack bags, tank bag and fender bag & a Kolpin chain saw holder.

Just went out yesterday to try out the engine mods and I am just amazed at this point. Here is what I know:

Top speed is not yet certain. Reached 46 but not that important here as we ride mostly mountainous terrain. In that regard this thing will scream up hill in HIGH RANGE! and not lug down or feel as though it is slipping the belt. At 6000 feet elevation it will leave a stock Sportman 500 or Magnum 500 in the dust. Don't know about the H.O. version because there weren't any with us yet!

In low range it is really nice to be able to just creep over obstacles or up really steep nasty terrain, although it is not quite as slow as the 325 magnum because of the tire size difference (putting the 26" tires on it before the gear change made it necessary the use more speed with higher engine rpm's that at times were comfortble).

Overall I am very pleased with the out come, however I am going to put the EBS back on and see how it works again. Without it of course it requires a lot more downhill braking. With it I may lose some of the top end speed (again not much of a concern) then again I am hoping I don't lose some of the low end that I have gained without it!

 

Thanks for the input. I'll let you know what I decide to do, ad how it works!