Polaris 440 Case Mod

akiqpilot · 03-29-2007, 03:11 AM

Here is a link to the 440 Pre Mix Mod. A few guys were asking for something so I threw it together.

This mod has been discussed here before but I finally put some text and pictures together. It is preferrable to split the case to perfor this modification like the Ripperd Mod did but I feel confident that if performed properly your '04 and newer 440 could last for many miles.

We use only Polaris VES Racing oil mixed 28:1. The motors are jetted fairly lean 290-320MJ depending on conditions.

Oil Injection would still be the preferred choice but this mod cost about the price of a base gasket.

Feel free to ask any questions or comments.

Enjoy.

440 PreMix Case Mod

fabioonachopper · 03-29-2007, 08:15 AM

great writeup

on the edge 02 · 03-29-2007, 11:36 AM

Very,very, informative!!!!! Thanks for sharing AK

ripperd · 03-29-2007, 10:12 PM

Excellent! I have had good success with this also.

gumper800 · 03-30-2007, 10:05 AM

pin ttt?????????????

gumper800 · 04-02-2007, 10:06 PM

PIN TTT

Guy... · 08-12-2007, 12:00 PM

whats the method of not spliting the case?

Guy... · 08-12-2007, 05:30 PM

you cant edit your post on hcs.. any ways so the 06 iq's have the case mod is already done from factory??

akiqpilot · 08-13-2007, 07:05 PM

Freddy

This modification is primarily for the Polaris '04 440, the later years would benifit from this mod as well but it definately isn't needed on '05 and newer 440's unless you expect to put over 3-4 thousand miles on them.

My link explains how to drill this hole without splitting the case, you still have to pull the PTO Cylinder but not split the case. Splitting the case would be the preferred method but this method does work and will last for a long time if you are careful not to allow shavings to enter the water pump gear cavity.

The later modle 440's, '05 and newer do not have to have this mod because they have a revised water pump and crank gear and maybe a revision to the cooling cavity in the case. These revisions basically eliminate the gear failures that plague the '04 440's.

Guy... · 08-13-2007, 07:09 PM

heys its guy from dootalk.

thanks alot for you help tom

03-29-2007, 03:11 AM	#1 (permalink)
akiqpilot Super Advanced Member Join Date: Dec 2005 Posts: 5,243 Location: South Central Alaska	Here is a link to the 440 Pre Mix Mod. A few guys were asking for something so I threw it together. This mod has been discussed here before but I finally put some text and pictures together. It is preferrable to split the case to perfor this modification like the Ripperd Mod did but I feel confident that if performed properly your '04 and newer 440 could last for many miles. We use only Polaris VES Racing oil mixed 28:1. The motors are jetted fairly lean 290-320MJ depending on conditions. Oil Injection would still be the preferred choice but this mod cost about the price of a base gasket. Feel free to ask any questions or comments. Enjoy. 440 PreMix Case Mod __________________ "Never argue with an idiot; they'll drag you down to their level and beat you with experience." ~ anonymous

03-29-2007, 08:15 AM	#2 (permalink)
fabioonachopper Super Advanced Member Join Date: Nov 2006 Posts: 575 Current Sled(s): 13 switchback 800 Location: ware,ma 10-11 Mileage: 1000 Age: 25 Riding Since: 1995	great writeup __________________ its FABIO ON A CHOPPER INTERNAL MOD---->

03-30-2007, 10:05 AM	#5 (permalink)
gumper800 Super Advanced Member Join Date: Feb 2006 Posts: 791 Current Sled(s): 1996 680 Ultra Previous Sled(s): 1987 Indy 400 Location: MN Favorite Riding Area: Dennison, MN 10-11 Mileage: 33 Age: 30 Riding Since: 1986	pin ttt????????????? __________________ MEDFORD DITCH BANGERS

04-02-2007, 10:06 PM	#6 (permalink)
gumper800 Super Advanced Member Join Date: Feb 2006 Posts: 791 Current Sled(s): 1996 680 Ultra Previous Sled(s): 1987 Indy 400 Location: MN Favorite Riding Area: Dennison, MN 10-11 Mileage: 33 Age: 30 Riding Since: 1986	PIN TTT __________________ MEDFORD DITCH BANGERS

08-13-2007, 07:05 PM	#9 (permalink)
akiqpilot Super Advanced Member Join Date: Dec 2005 Posts: 5,243 Location: South Central Alaska	Freddy This modification is primarily for the Polaris '04 440, the later years would benifit from this mod as well but it definately isn't needed on '05 and newer 440's unless you expect to put over 3-4 thousand miles on them. My link explains how to drill this hole without splitting the case, you still have to pull the PTO Cylinder but not split the case. Splitting the case would be the preferred method but this method does work and will last for a long time if you are careful not to allow shavings to enter the water pump gear cavity. The later modle 440's, '05 and newer do not have to have this mod because they have a revised water pump and crank gear and maybe a revision to the cooling cavity in the case. These revisions basically eliminate the gear failures that plague the '04 440's. __________________ "Never argue with an idiot; they'll drag you down to their level and beat you with experience." ~ anonymous

03-29-2007, 11:36 AM	#3 (permalink)
on the edge 02 Super Advanced Member Join Date: Feb 2006 Posts: 812 Current Sled(s): 08 IQRR,Proxr 440/800,Edge X,XLTSP, and Mercs Previous Sled(s): 86 Indy 400,94 XLTSP Location: Iowa Favorite Riding Area: Wisconsin 10-11 Mileage: 100 Age: 48 Riding Since: 1983	Very,very, informative!!!!! Thanks for sharing AK

03-29-2007, 10:12 PM	#4 (permalink)
ripperd Super Advanced Member Join Date: Dec 2004 Posts: 848	Excellent! I have had good success with this also.

08-12-2007, 12:00 PM	#7 (permalink)
Guy... Super Advanced Member Join Date: Mar 2007 Posts: 1,006	whats the method of not spliting the case?

08-12-2007, 05:30 PM	#8 (permalink)
Guy... Super Advanced Member Join Date: Mar 2007 Posts: 1,006	you cant edit your post on hcs.. any ways so the 06 iq's have the case mod is already done from factory??

08-13-2007, 07:09 PM	#10 (permalink)
Guy... Super Advanced Member Join Date: Mar 2007 Posts: 1,006	heys its guy from dootalk. thanks alot for you help tom

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