I am thinking about installing the 800 complete exhaust system on my 700. Is there anyone that has done this? Would it be worth it or am I just throwing money away? I have though about some of the after market systems but the out let on them would be in my bumper. Any help would be appreciated.

 

Ditto!

 

Just put the 800 header and air intake on even with the stoke can on you will see a diff.you will have to rejet if you put the air intake on.

 

Yeah, a lot of us are running the 800 header pipe, Pure Polaris (white bros) muffler and 800 airbox intake on our 700s. Like a friend of mine says, this setup + 700EFI = a 700EFI HO. The power gain is noticeable. No other modifications or adjustments are required on the EFI, can’t tell you what might be required on the carbed machines.

 

Floodrunner, Do you know if this affects the warranty in any way by setting it up as you suggest?

 

That’s a good question, and one that you should ask your dealer. The dealers have a lot of leeway on how they write up warranty claims. In many cases they have the choice to work with you or against you. If you’re into doing a lot of your own mods (like I am) you need to ask the dealer BEFORE YOU PURCHASE, what if I install bigger tires, lifts, etc. Will you honor the warranty?

Of course, this is a give and take situation. If you install something that causes a problem you can’t expect Polaris to buy you a new one. But if you put bigger tires on and the dealer won’t warranty your T-Bap because of it, find a new dealer. It requires reasonable behavior on both sides which means you’re dancing around in that dimly-lit gray area of interpretation.

 

It sounds like a worth wile mode to make. Since I'm a newbe can someone break down the parts and approx cost you'll need to make this happen. Also has anyone updated the CCV to keep it from dumping oil into the air box. from what I can guess into htis it sounds like 800 EFI heared pipes, new slip-on muff, new airbox . What parts do you need to make the airbox complete do you need to update the intake. Also will you need to update you clutch packs to hold the new power. I'm looking to make my toy a bit faster than a stock BF. I held my own on the last run we had. I got out run on top end.

 

800 Head pipe MOD
Header pipe- 1261445-029 $74.99
(3)Heat shields- 5244014 $3.32* front on 700 same as rear on 800
5248703 $1.46
5248702 $1.46
Header to cylinder gasket- 5811511 $18.32* same
Header pipe to muffler seal- 3610047 $12.49* same (donut)
--------------------------------------------------------------------------------------
800 AIRBOX SNORKLE MOD
Airduct/ snorkel- 5435932 $19.16
Airduct/ snorkel gasket- 5411422 $3.96* same
*Total for 800 mods (pipe and snorkel) w/ $5 S&H $102.07 (* w/o gaskets)

both of these mods can be done without replacing the gaskets/seals due to them being the same part number as stock 600/700/800 models are all the same part number.
the 800 header mod without gaskets will cost $81.23 and the Airduct/ snorkel mod without the gasket is $19.16.
Prices may vary this was with a 10% discount.

800 pipe silencer kit $270 (no snorkle_)
http://cgi.ebay.com/ebaymotors/POLAR...temZ4587020602

 

You should have a 155 main jet in from the factory (model years 2003-2004).
With stock airbox try a 162.5 or a 165 and work down after plug reads at WOT.
Maybe go down one slot on the needle clip.


I have a 162.5 in and its running good with a tan plug in the 50-80 deg. range (0-2k altitude) with a K&N and 800 pipe/snorkel.

I may need to jet up for colder winter weather under 40 deg., maybe a 165 or 167.5.
I bought 165 thru 170 mains at my dealer for $4 each.

Jim

 

Thanks for the info. looks like $$$ well spent. Now I jsut need a programmer to update my fule maps since I have efi.