is the 800 header worth the work i can get one for half price of new thanks and is it that hard

 

Yea its worth it. It gave mine some good grunt. Its not a real big job to put it on.

 

did you have to cut the end to the muffler and mod it do you have any pics

 

It will bolt right up to the muffler. Picture

 

did it give you more bottom and top end did you have to jet up 1or 2 sizes thanks

 

I would check your jetting right now and see where it is. Most of the polaris atv's are jetted a little rich from factory. The only way to tell if you need to jet up is check your plug after the header install. I gained more bottom end when I installed mine.

 

It workes great on mine it bolted right on I did the 800 snorkel too but I did jet up for the snorkel but the pipe should be good but you should check it after you put the pipe on. it gives more bottom end for sure and all the way up too

 

do a search lots of info....



The 800 header install instructions ...

-You have to unbolt where the fender & floorboard is put together.

-Unbolt the rear cab bolt its right next to the air box on top of the frame.

-Take the shifter rod off from the back.

-Take the 5 springs off and slide the stock pipe out between the fender & floorboard.

-Take the Y pipe off the head (6 mmm allen/ #40 torx) & the rubber adjuster that held the stock pipe up (its not needed anymore).

-You can go get new gaskets or use the old ones as I did.

-Slide the new header in just like you took the stock pipe out & bolt it to the head.

There are 3 modifications that will have to be done to make the header work.

-First the muffler will have to be took off and the mounting holes slotted to let it move forward 1/4" on stock silencers or some aftermarket ones.
You have to do this because the header pipe is shorter than the stock pipe.

-Second the shifter rod has to be mounted on the outside of where it bolts to the transmission linkage. Then you have to bend it just a little to clear the pipe.

-Last you have to trim a piece on the floorboard (just a small piece) right where the first heat shield is because it rubs the floorboard.

- You may need to shim out plastic side panel with L bracket etc for clearance to keep from melting.

-Start it and check for leaks.

- Do Plug checks and rejet accordingly.

photos at.... http://community.webshots.com/user/sportsman70003


BTW, the bolts on the header are a 6 mm allen socket or a torx #40 will work.
I used the orange/copper Hi-temp gasket sealer /maker on my head gasket and silencer donut without any problems or leaks yet.

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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

 

my 800 pipe mod picts