what are the differences between the two. wondering what it would take to make the 500 an H.O

 

The biggest difference of course is 20% more power which is great but the down side is it burns more gas, 25% more. To get the 20% increase in power you need a bigger carb (can't remember the actual size) and the Scrambler HO cam. There is one other quite important difference and that is the bottom end was made stronger on the HO. The steering was made lighter and all the brake lines are stainless steel braided.
As far as I can remember that's about it.
Almost forgot, the tie-rod-ends were upgraded too and what a difference that made. Now 1400 miles and still tight.

 

You need a 40mm carb.Stock SP500 is 36mm carb

 

thanks. 2 guys at work just bought 500's. one is H.O and the other one isn't. i thought it was just a coating on the cylinder. more differences than i thought.

 

What is the difference between the HO and non-HO?

I know these changes were made from 2000 to 2001 (have both in family).

2001-HO, improved both the brake pads and rotors. Switched to Stainless steel brake lines instead of rubber to improve breaking (and stop line bulge). Increased the diameter of the steering shaft from handlebars down. Went to the brass steering bushing. Improved the seal on the transmission for waterproofing. And added the Scrambler 500 HO motor. This motor is more then a carburetor and cam over a non-HO motor!

So to sum it up, the HO is quicker/faster, stops better, handles better and stays dryer. As for the handles better part any one who owns a pre brass bushing Polaris knows the plastic ones were loose in the first 10 hours of riding!

PS: as for the gas milage........ I run mine on the cinder and stone service roads next to RR tracks. My trips vary from 10 to 40 (each way) plus miles at a time. Me and my gear are about 400 lbs. and I run at average 35 mph. I may have "a good one" but it gets 20 - 25 MPG!

Mark

 

There is no comparison!

I have both and really like the HO. Although, I do like the lower RPM engagement of the 500 for plowing and rock crawling. I thought about making the 500 a mudmachine with mud tires, K& N and a clutch kit, but it would probably be cheaper to just sell it and get another HO that would perform just as well, especially with all the other improvements on the '03.

 

For 2001, the lower plastic bushing was replaced with a ball bearing.