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

great writeup

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

Excellent! I have had good success with this also.

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

PIN TTT

whats the method of not spliting the case?

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

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.

heys its guy from dootalk.


thanks alot for you help tom

were can i get the IsoFlex grease for a reasonable price?

so on the 06 440 does this mean i do not need to do the case mod to trail ride it?
also i might not need to split the case?

would you have to do this mod on a 07 600 mod?

The '07 Factory mod should have already been drilled from Polaris. I am not positive of this as we did not buy any '07 Mod Motors directly from the race department. There are two ways to figure out if your motor was drilled before it left Polaris.

1. Remove both Reed cages and look inside the Cylinders with the pistons at TDC. Use a 90* hooked poker (or something like that) and reach in under the Piston and see if you can feel the hole drilled in the case. Very easy to do, should take about 20 minutes total. I say look under both pistons because in '06 the instructions said to drill under the Mag Side Cylinder but you never know they could have decided to drill under the PTO side in '07 . The 600HO only needs to be drilled under one piston not both. And this will be a good time to look closely at your reeds to see if you need to replace them.

2. Call the Polaris Race Department and see if they know if the '07 case needs to be drilled. They are very busy and may tell you to just look for yourself so it might be better to just look.


Apple

The '06 440 does not need this mod to trail convert it. It may last a little longer if you drill this hole but it is not absolutely necesary like it is on the '04 440.

Is there any harm if it's drilled on both sides like case mod to 04 440? I know there flows some gas/air mixture from cyl to another when pistons move up & down.

Where there any holes drilled to waterpump cavity in 2006 factory mods before assembly? When I tore down my motor the mag side had a hole and I drilled one to pto side following the 440 premix case mod.

If there is harm so it's easy to tab and put skrew in the hole.. Ideas?

No harm at all Sape. In fact I think the bearings and waterpump shaft will last much longer with two holes drilled.

If your 600HO motor already had the Mag side hole drilled it was done by the previous owner. Motors that were designed for Oil Injection did not have a hole drilled into the waterpump shaft cavity. In '06 Polaris sent us a bullitin about drilling these holes if we removed Oil Injection.

I did not buy any '07 Mod motors from Polaris so maybe the '07 already had the Mag Side drilled from the factory.

You should be double covered now on your waterpump shaft oiling.

Hmm.. ok that helped a lot. Thanks!

When I bought this sled (from the 1st. owner) I asked about the case drillings etc. Anyway he told that he didn't do any of those, but I dodn't know if he was just playing stupid or what.

what about taking off the water pump housing cover to get shavings out?

what size gasket is the stock one for the cylinder base?


will i need to replace the o-ring's?

TTT

Sorry I missed this one Guy.

Taking off the water pump cover doesn't get to the gear cavity so you can't get shavings out that way. If you are careful and turn the motor up side down no shavings will get into the gear cavity.

The stock base gasket for late model 440's and most 600's is the .015" thick one P/N 5812494.

There are 3 other base gaskets available for these motors.

5813069 .006"
5813070 .010"
5813071 .020"

You can do a lot with your motors performance by changing base gaskets, but you have to know what you are doing as you decrease the squish.

hey guys, i have been looking for a 600ho and if i get one i want to run pre-mix. is this a must do on the 600ho's, or is it already done? how about the ves also?

i just pulled my 730 apart which is built with 440ho cases 600 crank and big bore jugs,, anyways its got the driled cases for the water pump and the oil was all over the place the gear had no problem getting lubed and looked to be in "brand new condition". Id say its got 1500 miles on it. and 90% was at 8 grand!

thanks AK

what would the different base gaskets do? i guess a thick base gasket would raise the cyl. up and you would have less compression?

[quote
Apple

The '06 440 does not need this mod to trail convert it. It may last a little longer if you drill this hole but it is not absolutely necesary like it is on the '04 440.
[/quote]



i trail rode it this weekend and it was pretty sweet to ride

hey thats nice how much one of those caust

okay Tom, question. I had a 04 440 motor that had the crank sieze at about 500 miles. my question is if i split the cases and do the mod are the cases still good, or are the junk along with the cranks?

It depends if your cases are within tolerance or not. The best thing to do is bring your bottom end to an engine tech or polaris shop and have them check it. Sometimes when the crank locks up, the bearing spins a little in the case and throws them out of tolerance. This can be fixed two ways, if it isn't that far out, the cases can be line bored to true up all the main bearing saddles. If the case is too screwed, you need to replace it. Most of the time the naked Eye can't tell if a case is good or not, so don't listen to your buddy who says "they look fine to me, throw a crank in it and go" because sometimes it works fine, and sometimes (like with my 900) the cases need to be line bored.

ok thanks. how much would it cost to fix if need be and how much are good cases worth?

how many miles will this give me on my 04 440 im trail riding it and i was wondering if i will get a good amount of miles out of doing this

Hi, This is great and really informative. Does anybody have any info on converting my 04 PROXR 440 to oil injection?? That is what I would really like to do. thanks.

The '04 440 does not have a check valve in the case to oil the center bearing.

The first thing you would have to do is drill the case and install the check valve for the center bearings. The Check valves are about .262" in diameter, so you would need to drill a .250" hole and work it just a tad larger. The check valve will just press into place.

The best method would be to split the cases and drill the hole. You could also inspect your bearings and gear for wear and decide if you want to continue with the '04 motor. I have also seen the check valves installed in the oil pump block off plate, then you don't have to drill into the case.

You would not add an oil line to the PTO Bearing, Leave the zerk and do not ever add grease to it. If you split the cases you would repack the PTO bearing with IsoFlex grease.

You would use the 600HO oil pump. The throttle cable from an '01 440. and have to decide what to use as an oil tank.

I am sorta liking the Polaris Race Tip about manual oiling the center bearing on the '08R. While not the perfect answer it sure seems to be working. This could be done to any motor that has the center check valve already installed.

And you could install a tiny tank just to oil the center bearing, the oil seens to gradually be sucked into the motor. My oil line holds about 4ml. and it takes about 4 gallons of fuel to suck it dry.

Here is how I have my '08R set up. Of course I remove the syringe after I shoot up........
Click to view attachment

lol.


is that a standard syringe? with the oil line pressed over.

what oil is that?

It's empty now. I put the syringe on for the picture.

The line stays in place, the syringe is removed and put in the tool box between useage.

You are supposed to use any 2-stroke oil.

I like how you keep the line on the injection fitting so you don't have to pull off the carbs every time. How often do you do that for a 08 600 IQ race Trail rode sled?

AkIQPilot: This is not even a new fix, some have been doing it for years. I got the idea from a pm I got, (not my idea of course) and I do think its great that you did a post on it, (BUT AT THE SAMETIME) when I put a post on it. You blew it off like it was a POS idea.
And that there was no way a (ONE WAY VAVLE WOULD DRAW OIL IN IT). Funny I guess that polaris had to post it first.

Just keeping things on the same playing field.