I recently traded my 05 700efi for a 06 500efi and noticed alot of difference in rpm's while running at a constant 25 mph from the 700 to the 500. The 700 ran about 4200rpm's at 25 and the 500 runs about 4900rpm's. I thought there was something wrong with my clutching because I thought the gear ratio's were about the same from the 700 to the 500. I took it back to the dealer and he took the clutch apart and checked it and ran it and said it was working fine. Did some checking to find out that in 2005 Polaris changed the gear reduction ratio in high, low and reverse on the 500HO. In 2004 the gear ratio in high was about 3.34/1 and in 05 and 06 they changed it to 10.49/1 in high. The 05 700efi is about 2.70/1, so that is a heck of a difference in gearing from the 500HO to the 700efi. I have heard that people with the 04 500's get more speed than the 05's and that would be the difference.

 

I noticed that my 05 500 runs at much higher rpm's than my 04 400 while driving around, I guess this is why.

Another thing to keep in mind is that 05 500+ come with 26 inch tires, were all 04 and previous had 25's. But that is still a large change in gear ratios.

 

tyler711

For 05 Polaris also changed the gear reduction ratio on the 400 too. It is the same as the 500HO now. I didn't check on the new 450, but it is probably the same as the 400 and 500. I don't believe the 700 or 800 changed at all. I just thought that it was a heck of a jump to change the ratio that much. Talked with my dealer and he says maybe they did it because some people don't know how to use low range and they are trying to curb people from burning a belt, which is probably true because I haven't used had to use low range yet for any of my driving habits. I will have to use low for pulling though.

 

I would have definetly like lower gears on my 400 - I need low all the time. With my new tires, I find that there are many times when even full throttle won't spin the tires in High. When plowing, I have once or twice almost not been able to spin them in Low, as well. On dry pavement, I have to hold full throttle for about one second before all for tires break loose. I know how bad that is for the belt. Seems like lower gears was a good idea.

 

Bump

 

Where does this gear change take place? In the transmission, or in the clutch? Seems like the latter would be a much easier and cost-effective solution for polaris.

 

I haven't had time to look at the parts diagrams for both years. I am not sure where the reduction is at, but if I had to guess it would either be the transmission or final drive. I could be wrong too, it wouldn't be the first time.