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Discussion Starter #1
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
 

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Discussion Starter #9
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.
 

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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[/b]



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

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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.[/b]



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?
 

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Discussion Starter #14
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.
 

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The 600HO only needs to be drilled under one piston not both.[/b]
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?
 

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Discussion Starter #16
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.
 

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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.
 

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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?
 

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Discussion Starter #20
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.
 
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