I am very mechanically inclined and understand clutching and motors and was wondering as this is my 1st Polaris 4 wheeler-- Is there any standard mods that are usually done? Like on a snowmobile you gut the air box and re-jet the carbs accordingly, clutch it depending on riding style--I don't like "kits" I'd rather make my own taking into consideration my body weight,motors recommended rpm range.etc.etc..any recommendations in clutching would be nice--I like EPI springs and am somewhat partial to AC weights then Polaris because of where the weights weight is placed--middle vs tip -even though they weigh the same.What are some of the standard mods everyone does to these 500cc sportsmans? I'm used to working on my Harleys and my 2-3 and 4 cyl. snowmobiles so I need some suggestions from those who are in the know. I am not looking to race I just want some good low rpm power for putting through the woods with the guys, doing yard work,maintaining sled trails and the like. How often should I change the drive belt? Rebuild clutches, or at least replace springs and check weight bushings and stuff like that. Can somebody just give me a basic rundown on RECOMMENDED MAINTENANCE please it will be greatly appreciated. MaineWheeler

 

first thing to realize w/ this bike is its nothing like a snowmobile set up besides looking like it. as where on say a polaris sled you can pipe and clutch it to gain a whole bunch of power. as far as the air box goes just remember that your going thru mud and water and dont want to get any in the engine. you can buy after market exhaust and maybe gain 2 to 4 hp and clutch it to gain a little better low end but most of the time you loose top end. as long as the belt doesnt get burned bad it will last a long time as the new ones have a life time warranty on them. w/ that many miles on it you could take the clutch cover off and keep and inspect the clutches and the check the belt. try to use low range as much as you can when working this bike hard or going thru hard areas and mud slow as it will save on the belt.

 

Are the ATV belts like sled ones as far as being better off running genuine Polaris belts instead of non-brand name belts? Also does changing weights on primary change rpm power range-- or am i better of leaving it as stock as possible? And tire changes-do the bigger tires play havoc with the rest of the ATV? Whats the recommended larger size tires without tearing up parts?

 

imo yes the polaris belts are the belt to run. when i used to race my polaris sled i tried many brands but none were better then the ome as far as being the best performance. most clutch kits you use when you up the size in tires to help better belt grip and a little more engaging rpms. if you go too big on tires then yes it puts alot more where and tear on the drive train and requires more maintance.

 

Your clutching on a Polaris is the same as you have messed with on a sled but the results are not as drastic.On clutching just use your tach to set the engagement where you want the weights to shift it out how you want the secondary is a little dif but on the standard type secondarys I run the 40 helix with a Aaen blue spring.Check the weight curves out I like the 10 serries on my Scrambler but you may like the S weights.I have mine set up for mid power with 53 grams (10AL).Your main thing on clutching a 500 is to keep the top rpms under 6800 perfer under 6600