modifications so far:
cam shaft Scambler
ported head , matched all gaskets
trimmed intake to match carb and head
installed no base gasket (used yamabond great stuff)this raised compression to 130
wisco .020 piston
D.G. exhaust (tapered the manifold to match exhaust port and removed a bunch of weld dripthroughs)
39mm Kiehin 162main, 35slow,1 1/4 turn air screw,
K+N filter
increased air box intake to 40mm to match carb increase
twist throtle
Polaris 5" tach from sled (you can use this and still have rev,neut,and temp lights.
27"bi-claws and tri-claws with 1" lift in front
installed self adjuster, reverse and drive chains in trans (if you have alot of mls on you sp install a new chain when it stretches to far it will ruin the self adjuster150$)
appearences have been changed by removing all racks and the ugly serpents head on the handle bars repaced by the tach and the low beam lights in the scrambler configeration

i'm still a clutch kit away from a great package
Questions for you?????????
how do i cluth this:
what rpms do i run this at for the most power:
is there a rev limiter and how do i bypass it:
how do you think it would look black with the factory gold and green decals:

i would love some input
together we will crush the grizz

 

Do you have any pictures? I would like to see what your Sp looks like without the racks. Also, did the modifications make a big difference in power? I have been considering the H.O. cam and a 42MM carb from Aaen Performance.

Magnum 500 Pics

 

no pictures yet
no real rreference on the gain because my bike was so screwed up to start with

 

I have never had one of these motors on a dyno but Polaris states that 6500 is the operating rpms for the HO motor. I really like the HPD shift drum conversion and their trail clutch kit. It kept mine in the operating rpm and brought my engagement to a perfect level. In high it comes out of the hole great but not super hard and yet in low I was able to keep my crawling and climbing capabilities. I don't think you would be disappointed with the HPD clutch set-up.

By the way joelpolaris those mods if tuned correctly make a BIG difference. My buddy did that to his '97 except he opted for the AAEN pipe. I am running stock carb and pipe with the other mods listed below and he walked all over me. He outruns a fairly well built 400ex to 50 mph before the 400 passes him. As the old quote goes "Speed cost money, how fast do you want to go". Some machines just take more money, lol.

 

to day i finaly rode my creation for more tha 10min. ran great first thin g then lost power and ran boggy. i tried everything, pulling the chock at wide open to see if it was to lean. closing off carb vent at wide open to see if it was to rich, nothing. plug looked a little dark but not fouled no luck there. bike will only tach 5500 and is slow to get there.
when i got home in discust i removed the cover hoping to find the clutch doeing some mystical crap, while i was there i took out that crappy EPI kit (the secondary spring keeps binding on the sheth tower because the crappy company gives you a spring that is too small in diamiter) they suck from what i hear on this forum and others .
back to my problem, i thought maybe gas was bad but the bike idles pretty good. it has alot of airbox noise i noticed after taking the cover and the k+n off (abnormal noise) all i can sermize from all this is that the cam timing is off .
when i put the motor together i checked it twice then when i took it to the dealer to have the carb jetted (still not perfect) the mechanic told me he had to reset because it was one tooth off so i just figured i must have just had too many beers and it was late.
now i think it might have hapened again what could be causeing this to happen over and over. maybe the adjuster is popping off (can this hapen ?)
well tomorrow after i tint a car and put in a window i wil fin out for sure if the timing is off (i will reply with my findings )
P.S love having a tach on my bike they should come with one
good bye for now i'll be back hear tomorrow

 

If your timing chain jumped, you are in bad shape. If it jumps far enough, you can smash the valves & piston together.


Rainman

 

well ive had the day to try to figure out whats wrong and i still dont know. cam timing was fine , tryed new plug and no air box and started throwing darts at everything that has ever gone wrong with anything that ive owned in my life . NO LUCK

taking the dam thing to the shop tomorow to have the coil, cdi box, and rev limiter box checked. thats all thats left. the bike still only revs 5500 with no belt on and is sluggish on the way up to that. i did notice that at its peak, the needle keeps poping back about 200 rpms but the engine doesn't seem to change speed, so i'm thinking mayby an ignition problem
i sould have some pictures in a couple days of my bomb if i can figure out how to put them on hear

 

Just another thought, are you getting enough fuel? I don't know about a sportsman, but my 500 Sc has a fuel pump.

Rainman

 

fuel doesn't seem to be a problem the bike lags power from the start. i tried holding it at wid open trottle and slowly open the choke (and old jeting trik to see if you are runing to lean to make power)and the bike stated to load up so i know it is geting enough fuel . it semes as i work away at the variables that i'm leaning more tward a spark isue
thanks for the input
together we will crush the grzz

 

i talked to someone to day that sid they thought that my bike was rev limited to around 5800 if tru ive fond some of my problem .
i'm going to tri to get my dealer to call a polaris tech and fid out for sure . if so i know where there is a parted out scrambler that should have the right speed limiter

boy i wish i bought a new bike

together we will crush the grizz