OK guys. We all know are Polaris machines are great. We also know they are heavy. What are some good ways to shed some weight (keeping electric start in place). Anyone who has done this or looked into it. What can be removed (rack?) or replaced (wheels?) and what is the weight savings?

325

2000 TrailBoss 325 with RCR Stage 1 kit

 

You could remove the stock skid plate and putting on an aftermarket one. Get some liter rims. Maybe some aftermarket hadlebars, like pro tapper.

 

I would keep the stock skid plate, as it is already as light as you will get, it is composite. You didn't mention what machine you had, but I assume it is a utility model? Some of the following would work on the recreation/utiliy models too.

On the sport models (scramblers, sport, trail blazer), I have seen people replace the handle bars with aluminum, same with the wheels, replaced with aluminum. I have seen the floorboards removed and foot pegs installed. Oil injection removed and go to pre-mix if it is a 2 stroke. You said you don't want to do this, but I have seen the battery and starter removed. And almost every aftermarket exhaust is lighter then the stock pipe/muffler by a few pounds.

 

I hear so much about shedding weight off our quads. For trail riding, even agressive trail riding, what is 10 lbs. difference gonna make? I can understand if it were 50 to 100...but less than that seems pretty minimal?!

Maybe I should not wear that extra jacket and those heavy socks...LOL

 

i thought the wheels were already aluminum on the 99 sport and 2000 and up scrambler models, thats what they claim in the features.

matter of fact i didn't think polaris still used any steel parts besides the axel.

 

What is the weight savings on a set of alum. rims over steel. Also I once heard that losing rotataing weight is worth twice as much as losing non-rotating weight.

325

 

You are right, wheels are unsprung weight. I am not sure about the weight saving amount, but I do know it helps. Besides that, it looks bad ***.

There is a Scrambler 400 2x4 that I know of, he has reduced his weight by about 40lbs with the mods I listed above. 40lbs is a noticable amount.

 

A commonly overlooked place to get lighter is with the rider! (my case especially)

 

325
I have reduced some unsprung rotating weight by replacing the steel disc guard for the chain with an aluminum piece. I drilled it with holes to lighten it even more it has held up well so far. I even put aluminum hubs on also.
I did this because I put Bearclaws on with .190 aluminum wheels and wanted to counter act some of the added weight of the new wheels and tires.
Did I notice a difference? Not really. I`m sure it helped there was quite weight difference from steel to aluminum. Plus it looks good.

98 Scrambler 500

 

You save an average of 7 lbs. by switching to aluminum wheels. Have you ever held a Douglas or an ITP rim in your hand? You can't even tell it's there they are so light. It's amazing.