Hi everyone, newbie here.
I just finished my engine swap on my 2002 Sportsman 700 chasis to a 500HO out of a crashed 1998 scrambler. I thought it would be a little bit easier than it was. It really wasn't too bad though. I had to cut the 700 mounts out and move the mounts from the scrambler over. I'm really happy I got my Millermatic210 last year, it made easier to do. Getting them clutches off the motors was the hardest part for me cause I didn't have the propper puller. And some minor electric goofs on my end which I shouldn't have done, forgeting to hook up a couple ground wires. So at first the motor wouldn't fire then the when I got the one ground wire hooked up the motor fired but wouldn't shut down. But I did get it right. I also added a fan switch after lurking around here for a while and read others have done it. If I did it with the 700 motor I probably would still have it running.

While putting the body back together, I pitched my old nut and bolt with angle iron custom whinch mount I made up cause I didn't want to spend money at polaris for their metal at the time and welded up a good one that doesn't have any flex.

 

So where's a picture???

 

Sorry no pictures yet, maybe this weekend. You'd hardly be able to tell from its appearance, other than the recoil on the right and the oil tank on the left. I also used the smaller radiator from the scrambler cause the hose ran to it better.

 

Did you keep the sp700's gearbox and drivetrain???? Just wondering what your top speed is now and how quick it is off the line??? Since the top speed of both machines is pretty close...say around 60 mph... and the 500 engine redlines at over 8000 rpm (I think) but the 700 twins redline at just over 6000 rpm, i thought they might be geared a lot differently. let us know, I was curious of this exact swap myself. Thanks, Dan.

 

my 700 tops out at 68.9 mph and my 500 ho tops out at 57.2 mph at 7000 rpms so if he did use the stock gear box of a 700 with a 500 ho engine it would prolly top out at close to 75 mph but would bogg out on take off untill it would hit the power band.

Bob

 

I kept all the parts on the 700 except the motor and the clutch, drive pulley and drive shaft going to front differential. I took it out and I got it up to 50 with more throttle to go. I just don't like going too fast with these things. It does take off the line a little bit slower than the 700 motor when it ran right did but I expected that. Now on the clutch, the 700 were the belt rides on is larger than the 500 clutch. I didn't measure the distance the two points were before but I think the 500 sits further away so it uses a small part. I also had to use the scrambler gas tank cause the 700 tank bottomed out on the top of the 500 motor. And another benefit is the 500 is by far easier to change the spark plug on. The 700 was just a pita. The reason I used the scrambler shaft is cause it is smaller diameter than the one on the 700. With the 700 shaft, it was too close to the bottom of the 500 motor for my liking.

Please forgive my wording above, I don't know all the tech terms to refer to the parts as.

 

I have some pictures up now. I did take it out today and cleared snow from the driveway closest to the house. I had not running issues yet. One thing I did notice is the fan never kicked in on its own after 5 minutes or so, and I really didn't want to risk another motor so I used my switch to turn it on. after I finished doing what I wanted to do I parked it and shut the fan off, and it still was not on under its own power. Anyone have any idea how hot it has to get before it comes on through its own power?

 

I believe the 700s radiator is bigger than the 500s so it will take longer before the fan kicks in. In the cold weather my 500 will run for about 10 mins before the fan kicks in. I added a buzzer to my Hi temp light because when riding I'm not looking and the pod where the light is. This hunting season my fan seized so I would run the quad until the Hi temp light came on at which time I shut down the engine and let it cool down. If I didn't have the buzzer I would miss the light risking engine damage.

 

Yes the 700 radiator is a little bit bigger, but since I didn't use it and went with the scrambler one this shouldn't change much from that viewpoint. I did use the bigger fan though. And since I also ran it while using it maybe that is one reason the heat sensor switch didn't kick it in.

 

For not knowing the correct terms, you did one heck of a good job. Congrats!!!