Polaris Engine Swap
#1
I have a 1996 Xplorer 400 and I was wondering if a Polaris 500, 335 or 325 engine could be easily swapped with my 400 2-stroke.
The engine in my bike is fine, it is just that the blue smoke is getting to me. If I sold my bike I would have to put at least another $5000 with it to get a decent 4-stroke 4x4 . . . so I thought about buying an older 4-stroke Polaris quad (for parts) and get an engine swap. I could then sell my 400 motor to a Trailblazer owner to recoup some of the cost.
An engine swap should be possible because look at the SP 500 and SP335 . . . the same bike but with different engines. I know that back in 95/96 Polaris made a Xplorer 500, but it was shaft drive.
Correct me if I'm wrong, but are not the frames on the Xplorer, Sportsman, Xpedition and Magnum the same - except for the rear suspension of course. If the frames are similar therefore the engine mounts should be the same. This would make for a "simple" swap . . . shouldn't it?
Other things I was thinking about were:
- transmission should mate up to the engines in the same location
- carberator linkages may be different
- air box may be different
- hoses are easily rerouted
Does anyone know if this is possible? I know that anything is possible with enough money . . . but is this an economical and reliable thing to do? Any help or direction would be greatly appreciated.
The engine in my bike is fine, it is just that the blue smoke is getting to me. If I sold my bike I would have to put at least another $5000 with it to get a decent 4-stroke 4x4 . . . so I thought about buying an older 4-stroke Polaris quad (for parts) and get an engine swap. I could then sell my 400 motor to a Trailblazer owner to recoup some of the cost.
An engine swap should be possible because look at the SP 500 and SP335 . . . the same bike but with different engines. I know that back in 95/96 Polaris made a Xplorer 500, but it was shaft drive.
Correct me if I'm wrong, but are not the frames on the Xplorer, Sportsman, Xpedition and Magnum the same - except for the rear suspension of course. If the frames are similar therefore the engine mounts should be the same. This would make for a "simple" swap . . . shouldn't it?
Other things I was thinking about were:
- transmission should mate up to the engines in the same location
- carberator linkages may be different
- air box may be different
- hoses are easily rerouted
Does anyone know if this is possible? I know that anything is possible with enough money . . . but is this an economical and reliable thing to do? Any help or direction would be greatly appreciated.
#5
#6
Loyal,
Fom my understanding is that the engines should swap just fine. I have been looking onto the same thing. I have a 95 trailblazer and I just prefer the four stroke motor over a two stroke. I like the smoother longer power band of the fourstrokes. I have been contemplating puting the 325 or the 425 motors in my trail blazer. My biggest problem is finding a complete motor!!! I am not sure but I know the tank sizes are different on some machines. so you might run into a clearence problem with the top of the motor and the tank. If you do you should be able to re-shape the tank to allow the proper clearence. Other than that I haven't come across any problems with my research.
Fom my understanding is that the engines should swap just fine. I have been looking onto the same thing. I have a 95 trailblazer and I just prefer the four stroke motor over a two stroke. I like the smoother longer power band of the fourstrokes. I have been contemplating puting the 325 or the 425 motors in my trail blazer. My biggest problem is finding a complete motor!!! I am not sure but I know the tank sizes are different on some machines. so you might run into a clearence problem with the top of the motor and the tank. If you do you should be able to re-shape the tank to allow the proper clearence. Other than that I haven't come across any problems with my research.
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