I have to agree on the 400s being a great bike.I have had a few and loved them.The only draw back is they were almost too responsive for tight technical trails.That is what I ride mostly and have my 500 set for it.Polaris yellow primary 10ALweights(10RH work good but got my top rpms up to 6800 which isnt good on a 500)TEAM roller secondary with 44-40 helix and a blk/yellow spring(what is recommended for a 400)but with the lighter spring and steep helix I have great mid range power great back shift and good throttle response without wheelies all the time.Now for shocks and those settings I will keep them to myself for now.But as you know all the power isnt worth a hoot if you cant get it to the ground and control it.

 

Is that Helix that you are using in a Team Roller Secondary clutch?From the numbers that you have given it sounds like it is a custom split cut design Helix like the ones that the factory Polaris secondary clutches use.I've never seen Team use a Helix for their roller secondary's that didn't have a three number description.The Helix that I'm using in my Team Roller Secondary is a 65-63-60.

Over the years that I've owned my Sport and have been racing it I've tried just about every secondary clutch setup on the market.I've ran the factory Polaris secondary with custom cut Helix's and different secondary springs, the shift drum conversion kits like Aaen and HPD sell, the Super Duty Clutch Button Kit that HPD sells and have found that the Team Roller is the best out of all of them.The biggest advantage that the Team Roller has over the others is that it runs cooler than the other designs and extends belt life.

The biggest flaw in the design of the factory Polaris primary clutches design is the teflon coated plastic buttons IMO.For a stock or piped quad they work decent, but still suffer from wear and once you start making serious power with more compression, port work and a power adder like Nitrous Oxide then they just seem to wear out very fast.The factory secondary also seems to create a lot of heat with aggressive riding even on a stock quad, but it seems to get much worse on modified quads.

I've been racing at the track before and have taken my clutch cover off between rounds to check the condition of the belt and clutches and have seen the factory secondary get so hot that you couldn't touch it with your bare hand.With the Team Roller Secondary I haven't seen that problem yet.

I agree with you 100% about the suspension of the Gen 3's needing to be better.Over the years I've tried several different things to improve mine and still haven't found anything that I really like.I don't want to hi-jack a clutch thread or get too far off topic by getting into suspension talk so I'll leave this subject alone.

 

My actual helix number I think is 52-44-40
Make a thread on suspension there is alot that most dont understand about the gas shocks