okay, I finally found a 40mm HO carb for my 96 sportsman. I have a few questions...

Will this just bolt up or do I need to change anything else? Also, If I buy a dyno jet kit for it, I'll want to buy a kit for a 2001 500 HO since that's the carb I"m jetting right?

I'm working on getting the HO cam... just don't have one picked out quite yet. I called web cam, but they're wishy washey on whether or not it would work in my engine.

 

you may want to change the intake manifold on the head, i believe the ho it larger. as far as jet kit, you may have to play with it. because youre not really putting it an ho. as far as the cam i think it will fit. i can check the journal specs for both tomorrow if you want and get back to you. i know if ordering the stock cam it changed pt # to newer model. the cam will also affect your jet kit.

 

I put the H.O. carb on my 700 which had the 34mm carb. The intake manifold will slide over the H.O. carb with a little soap and after its on for a while it will strech and be easier to put on the next time. If I'm not mistaken the only difference in the H.O. & non H.O. is the carb and cam. If you put the cam in I would think that the carb jetting would be about the same as H.O.

 

The heads are the same part number between 96 and 2001 at least, so I would think that any cam would work in my head. If that's not the case, I guess let me know.

I can't find anything on the parts breakdowns other than something called an "adapter" where the intake would go. It looks like a short elbow. Is this what you are calling the intake manifold? If not, and you help point it out on the parts breakdown so I order the right part.

So here is my final setup that I'm looking at...

600 stroker with 11:1 piston and .20 overbore
HO cam
40mm HO carb

They said that they'd be able to get me close on the jetting, and I'd have to play with it to tune it in. Obviously I'd also benefit largely from an exhaust kit, but I'm out of money for now trying to leave some for misc expenses that come up to complete the project. Is there anything else I'm missing?