07 polaris sportsman 800 mods into a mud bike - Polaris ATV Forum
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post #1 of 19 (permalink) Old 09-02-2019, 12:29 PM Thread Starter
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07 polaris sportsman 800 mods into a mud bike

gotta 07 sportsman 800 efi twin stealth edition with the dual exhaust. has wild boar rad relocate and snorkel on stock size (26in) bighorns.

I pulled the snorkel apart as it had rips and holes throughout, how should i go about rebuilding this?

I installed a 4in lift, now looking for a set of fairly (like $4-600) 30x10-14 tires/wheels used or new, open to suggestions

Exhaust is cracked, how should i fix it?

seems to not have 800cc worth power.. feels the same as my 500cc, and backfires after high rpm, thinking tps is off?

looking for a set of aftermarket led headlights to fit this model, cant find any.. not a huge deal but current headlights (the lower ones) have sand in them and are halogen

The belt is going too, starting to smell it burning and feel it slipping, is just a belt good or is it worth putting a $500 clutch kit in?? looking to pop wheelies, have good acceleration and be able to cruise at 50-60mph, im fine with using low for mud bogging if necessary..

Thanks!
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'07 polaris Sportman 800 efi twin stealth edition le- le wheels, 26in bighorns, 4in lift, rad relocate, snorkel

'04 Polaris Sportsman 500- aftermarket polaris rims and 25in executioner tires. 2500 warn winch, aftermarket rear shocks, 2in front lift

'01 yamaha warrior 350- aftermarket DG exhaust
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post #2 of 19 (permalink) Old 09-02-2019, 12:34 PM Thread Starter
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Here's some pics
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Corbett1973 likes this.

'07 polaris Sportman 800 efi twin stealth edition le- le wheels, 26in bighorns, 4in lift, rad relocate, snorkel

'04 Polaris Sportsman 500- aftermarket polaris rims and 25in executioner tires. 2500 warn winch, aftermarket rear shocks, 2in front lift

'01 yamaha warrior 350- aftermarket DG exhaust
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post #3 of 19 (permalink) Old 09-09-2019, 11:17 AM Thread Starter
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ok so first priority: what clutch should i get for this puppy? and what about the backfiring? any help would be appreciated!

'07 polaris Sportman 800 efi twin stealth edition le- le wheels, 26in bighorns, 4in lift, rad relocate, snorkel

'04 Polaris Sportsman 500- aftermarket polaris rims and 25in executioner tires. 2500 warn winch, aftermarket rear shocks, 2in front lift

'01 yamaha warrior 350- aftermarket DG exhaust
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post #4 of 19 (permalink) Old 09-09-2019, 12:16 PM
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Quad shop customs clutch kit from RVS performance.

I'd look at replacing the exhaust pipe if its too rusty to weld back together.

So far as the lift, you are probably going to have problems breaking axles with that much angle on them. If you do then look into the 1.5" forward a-arms. That should give you enough clearance for 30s.

Headlights, check out Hays Fabrication. Or do like I did and mount a couple of cheap LED cubes to the front bumper.
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-j-rod
_______________________________________________


'11 Sportsman 800
- 26" QBT 672s on 12x7 and 12x8 Vision 158s
- QSC clutch kit from RVS Performance, OMC Gaskets, Rhino Axles F&R
- ODI Grips, Polaris Handguards, Kolpin Fenders, EPI HD rear springs
- Polaris bumpers/Rack extenders and HD front Springs, Badlands 3500 winch w/syn line

'18 Rzr 170 - kids ride

'01 Scrambler 500 4x4 (sold)

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post #5 of 19 (permalink) Old 09-09-2019, 12:24 PM Thread Starter
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i heard somewhere that the aftermarket exhaust doesnt give any more power over the dual exhaust on these bikes? would it be worth welding? its not rusted at all. still got factory paint on it.. almost no rust anywhere on bike. i think ill be good on clearence up front with the 30s. do you have a suggestion for a mud tire for this atv?

'07 polaris Sportman 800 efi twin stealth edition le- le wheels, 26in bighorns, 4in lift, rad relocate, snorkel

'04 Polaris Sportsman 500- aftermarket polaris rims and 25in executioner tires. 2500 warn winch, aftermarket rear shocks, 2in front lift

'01 yamaha warrior 350- aftermarket DG exhaust
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post #6 of 19 (permalink) Old 09-09-2019, 12:31 PM
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I dont know anything about aftermarket exhaust other than it gets annoying on a long ride. So far as mud tires outlaw 2s seem to be the go to for most of the mud guys.

-j-rod
_______________________________________________


'11 Sportsman 800
- 26" QBT 672s on 12x7 and 12x8 Vision 158s
- QSC clutch kit from RVS Performance, OMC Gaskets, Rhino Axles F&R
- ODI Grips, Polaris Handguards, Kolpin Fenders, EPI HD rear springs
- Polaris bumpers/Rack extenders and HD front Springs, Badlands 3500 winch w/syn line

'18 Rzr 170 - kids ride

'01 Scrambler 500 4x4 (sold)

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post #7 of 19 (permalink) Old 09-09-2019, 12:44 PM Thread Starter
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yea id love to have a pair of those but i dont want to swing the cost... im hoping to find a used set on craigslist or something. i saw a set of 4 29.5s with the wheels for $400 a while back but didnt have this bike at that point.

'07 polaris Sportman 800 efi twin stealth edition le- le wheels, 26in bighorns, 4in lift, rad relocate, snorkel

'04 Polaris Sportsman 500- aftermarket polaris rims and 25in executioner tires. 2500 warn winch, aftermarket rear shocks, 2in front lift

'01 yamaha warrior 350- aftermarket DG exhaust
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post #8 of 19 (permalink) Old 09-09-2019, 12:55 PM Thread Starter
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oh and ive heard that the stock primary clutches on polaris atvs sometimes wear out? would it be better to go with a whole aftermarket primary or a clutch kit?

'07 polaris Sportman 800 efi twin stealth edition le- le wheels, 26in bighorns, 4in lift, rad relocate, snorkel

'04 Polaris Sportsman 500- aftermarket polaris rims and 25in executioner tires. 2500 warn winch, aftermarket rear shocks, 2in front lift

'01 yamaha warrior 350- aftermarket DG exhaust
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post #9 of 19 (permalink) Old 09-09-2019, 01:59 PM
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How many miles and hrs in the machine?

Also the 800 isn't a HP monster it's a torque monster. You're not go to have the rip the bars feeling out of it. But it does keep pulling and pulling with what seems to be endless power. I do know what you mean though out of the gate the 800 isn't anything to write home about!!! But then again it isn't a v-twin. It's power lies in the mid to upper range.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #10 of 19 (permalink) Old 09-09-2019, 02:01 PM
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Quote:
Originally Posted by Slabach View Post
oh and ive heard that the stock primary clutches on polaris atvs sometimes wear out? would it be better to go with a whole aftermarket primary or a clutch kit?
I'd pull the belt cover and check everything out to see how worn everything is in there. You might be able to get by with just a clutch kit. Replacing the primary with aftermarket will most likely not be cheap. CV tech primary for example will be 350-550 which is about twice what a clutch kit would be.

-j-rod
_______________________________________________


'11 Sportsman 800
- 26" QBT 672s on 12x7 and 12x8 Vision 158s
- QSC clutch kit from RVS Performance, OMC Gaskets, Rhino Axles F&R
- ODI Grips, Polaris Handguards, Kolpin Fenders, EPI HD rear springs
- Polaris bumpers/Rack extenders and HD front Springs, Badlands 3500 winch w/syn line

'18 Rzr 170 - kids ride

'01 Scrambler 500 4x4 (sold)

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