BACKGROUND: I bought my son a 2005 Polaris 90 for Christmas. I purchased it used and I started but didn't drive it. It is in brand new condition (nubs still on tires, runs/starts perfect).

PROBLEM: After i got it home, I jumped on it to ride it around and this thing is modified like crazy. It has the K&N filter, hotseat pipe & CDI box, bigger front sprocket, etc-- that i know of (what else should i look for?). The end result is that it has no low end at all. It has to rev (RPMs) like crazy before the clutch engages, and then just holding the throttle constant it hits a powerband that shoots it forward very fast. Somone put a lot of money into this machine. My son is an experienced rider, though only 6, but a lot of what he likes to do sometimes is to "crawl" (we are a Jeeping family) or offraod slowly like we do in the Jeeps. With no low end on this machine, there is no crawling to be had, and I am concerned by the fact that it seems to only have 2 speeds: Stopped, or Very Fast.

QUESTION: How can I most inexpensively restore the low end? I have nothing against after-market upgrades, I just want him to be able to work the throttle and go slowly if he wants and accelerate when he wants. I took it to the local Polaris shop (stupid! stupid! stupid!) and $180 later they had tried a few different jets in it and said it was "a little bit better". I had to point out to them that the front sprocket being bigger was not done in an effort to restore low-end power, as they had speculated, but actually was hurting the low end. I plan to replace the front sprocket. What else should I do?

-natius

 

I'm no expert but I'm pretty sure the clutch spring is no longer the stock one either and that dramatically changes your ability to easily take off the line gently.I would say you might start by restoring the spring to stock or somewhere in between what you have and stock.

 

<div class="FTQUOTE"><begin quote>Originally posted by: Sunman

I'm no expert but I'm pretty sure the clutch spring is no longer the stock one either and that dramatically changes your ability to easily take off the line gently.I would say you might start by restoring the spring to stock or somewhere in between what you have and stock.</end quote></div>

Will replacing these springs be okay while leaving all of the other mods that have been done--Pipe, CDI, Intake, etc?

If there is no problem, how hard would it be to do by myself?

 

I think all will be fine I wonder how much different the sprockets are from stock. You didn't perhaps get the origional sprockets did you? I wonder if the chain length has been changed.I just changed the clutch spring in our trailblazer 250 and it was sooo easy and I'm not that knowledgeable, but I was glad I bought the shop manual and had it and an impact wrench for the center clutch bolt.

 

<div class="FTQUOTE"><begin quote>Originally posted by: Sunman

I think all will be fine I wonder how much different the sprockets are from stock. You didn't perhaps get the origional sprockets did you? I wonder if the chain length has been changed.I just changed the clutch spring in our trailblazer 250 and it was sooo easy and I'm not that knowledgeable, but I was glad I bought the shop manual and had it and an impact wrench for the center clutch bolt.</end quote></div>

What is the best place to order the original clutch springs? Everywhere I look online I can only find places selling aftermarket ones that do the same as the ones I have in right now-- high RPMs before engaging, etc.

Also, where did you get your repair manual? Is there one that is better then another as far as the manual goes? I work on Jeeps, so ATVs are kind of new to me.

 

I would buy both from my local polaris dealer. In my case they are good people and deserve the business.