What gearing would you recommend for this machine? Customer has two friends that ride 900's and would like to maybe give 'em a run through the twisties and out of corners. Would sacrifice some top-end in order to make it a little more snappy.

I have seen conflicting setups. Some people run 25/38 and others 26/41. What are the characteristics of these two combos?

Sled is stock with the exception of airbox baffle plate/horn removal, Boyesen RAD valves and D&D Quiet Can. I will also be clutching once we get some snow.

-Twiggs

had an 02 800 ran 24/39 switched to a 25/38 was awsome!!!!!!!!!!

Thanks for the quick reply :beerchug: Anyone else chime in on this one?

I tried 25/38 and it was terrible on all but glare ice for topend on the lake. Definately did not add to the "snap" your looking for. I like 23/39. Gear down not up. I did the same thing with my 900. Dropped from 26/41 to the 24/39. I weigh 210+ though. A skinny guy might like to gear that high, but I doubt it.

IN BOTH MY 800's I RAN.............


-reverse gearing
-Goodwyn clutching / works mint right outta the box with zero fiddling or issues
-pay special attention to clutch alignment and run your belt on the tight end of spec for deflection
-run the track as loose as you can get away with
-no gains with rad valves in my previous 800 / not happy with the wild jetting swings they seemed to cause when the temps would go way up or way down / took em back out and all returned to normal.
-dump the can / it's killing power.............did on mine.
-jet to your elevation (ran 410's in mine)
-shelf out helps upper mid / high but hurts in low / lower mid range
-loosen up the limiter straps until just barely loose when flat on the ground / toss the rear blocks in the trash, now your sled will transfer and hook up.

Reverse gearing = 24/39 :div20: :div20:

Error, my bad, I was thinking 24/39 on the 900. (zr sled head's current ride) I still say 23/39 on the 800

Not douting your word or puttin down your thoughts but..................both of my 800's were animals outta the hole using that set up, no slouch mid / top end either, put a few 900's to shame (a couple of guys that post here in fact).
The reverse kit thats in my current 900 has already gone through both of my 800's (cheap skate aye??).

LOL

Stock gearing is actually pretty good for the grunt this sled has. I have tried to run 23/40 and feel it is too low, too much track spin and not smooth across the shift. With proper clutching I have found that 23/39 is by far the best!

After reading the other posts here you guys will think I am crazy, but I went with 20-41 gearing. With the gearing, a speedwerx clutch kit, and a 1.5" track this was by far the funnest sled I have ever owned. A ton of snap at any speed and plenty of top end still - 90-100mph who in the hell needs to go faster. The thrill is going from 0-70 in short order not just traveling at 100mph.

You guys have left me with waaaaay to much to ponder now :div20: I have the clutching pretty much narrowed down. The main goal is pretty much trying to out-do or at least suprise the two 900 ZR's he's going to be running with all winter while appearing stock.

The 900's are stock with the exception of Airbox mod, reeds, shaved heads, timing key and clutching. All done by Birch Point Cats. I gotta come up with something while retaining a stock appearance on this 800. Like I guess the same "easy" mods that they have done. But your first impression under the hood is " wow, that's stock?" other than the VForce 3 reed cage tags sticking out. You still gotta look for them. I was told not to use the VForce reeds on the 800/900's seemed to work better with the Boyesen RAD valves.

Okay guys, by Friday I have to have at least the reed choice and gearing laid out. Good prices to be had this weekend but I will be shopping Friday. The rest I have some time.

Any thoughts and ALL your help has been appreciated thus far :beerchug:


The general consesus seems to be 23/39. I guess I'll try that first. I assume it will work with the stock length chain?

-Twiggs

23-39 gearing will work with the stock 72 pitch chain, but it will have plenty of slack. The sled comes with 24-39 gears so you are not gearing it down enough to notice (other than slack in the chain). I still say go much lower with the gears if you want the sled to be "quick". A buddy of mine had the same sled as well, but his was stock. We would race with my sled having the setup I described earlier and it looked as if he was on a 600.

Low gears=quick
high gears=top end speed, but slower acceleration

If you trail ride only and at higher speed than you probably want the taller gears.

I have run both the 23/39 and the 23/40 gear combo's in the 800. I like both but I believe the 23/40 is more efficient because there is less slop in the chain while only losin 2.5 to 3mph top end over the 23/39 running the machine at 7200 RPM's. Both can use the stock 72 pitch chain. Both combo's will go over 100mph and have excellent acceleration Both are great trail setups, not lake setups.