Had a friend purchase a used 700 from a dealer and they really broke it off in him good. Long story short, they messed his engine up and claimed no responsibilty. It needs so many parts it ain;t worth fixing. ut he owes too much on it to erite it off as a loss. I was able to get my hands on some parts including an 800 crank. From what I can tell with all the cross referencing of numbers and comparing engine service data is the only difference is crankshaft and piston kits. The bore is the same but the piston pin is smaller on the 800 than the 700. This allows the rod to be slightly longer and give you the extra stroke for the cc upgrade. Has anyone here done it before???? If so, is there anything I need to know or worry about before I start ordering the rest of the parts I need?

 

You are good to go. get the 800 header pipe, check clutch spring's, they are different, ECM is different compared to my 800 and buddy's 700. I think that's it.

 

When I say ECM is diff, fuel code's must be different because I had update done to mine to richen it up and he went to do his and Polaris would not except his ECM thru there computer to update it and fatten it up.

 

Ncrider I cant wait to see how you make out.This is something ive thought about doing for a while now.I talked with my dealer about it.I just cant get myself to do it till I brake something.While its running good im going to leave it alone.good luck.

 

So far, I'm curious to see how a carb will run on the 800. I set the 800 crank in the 2002 case and everything cleared and looks good. Looks like a about 1/4 inch difference in height of rods when comparing the 700 and 800 cranks. I'm assuming the smaller pin makes it able to attach deeper in the piston to compensate so it will not hit the head. The jugs I think are the same.

 

A 40mm carb will work good on the 800 [img]i/expressions/face-icon-small-wink.gif[/img]

 

All the parts wll be in tomorrow. Going to be a busy weekend but hope to atleast start the build. Will let you know how it works out.

 

Day one, Everything fits like a glove except for one thing. The one thing I did not tink to check. The balance shaft will not clear the 800 crank. I'm debating on grinding the balance shaft to make the clearance but I don't know if it is worth the chance on a vibration that could cause issues later. It would not take alot to clear. I'm gonna think on it. Anyone ever compared the 2 balance shafts?

 

Project done!!!! It worked, and it runs great and lots of power. Here is what it you will need.

800 crankshaft
800 piston kit (2)
journal bearings for crank and balance shaft (crazy not to change them)
800 counterbalance shaft
the nut that holds the magneto on (different threads than 2002, maybe the same on newer models)
crank seals and waterpump seals and gaskets are a good idea since it is apart. (I changed every seal and gasket on it)
base, head, side cover gasket
oil, filter, coolant
sealer for crankcase

*NOTE* The counterbalance difference is really nothing. You could grind the inner side of the wieghts on it to make clearance. That is the only difference. I ordered one because I did not have a comparison. Had I had one to compare I would not have ordered it.

I have not determined jetting on it yet. It already has a K&N jet kit on it so it may be fine. The owner is going to ride it nd check the plugs after a few hours and we will make a judgement from that.

 

Thats awesome NC Rider!! How bout some vids of it running? I went through your myspace link to see if you had some pics or anything but you didnt. I'm sure you got alot of guys thinking right about now, looking up part #s and tallying the prices...