2005 Sportsman 500 Serious power mods

1585 Views 11 Replies 7 Participants Last post by polman500, Feb 15, 2022

TheNotSoMiniMiniMechanic

Discussion Starter · Feb 14, 2022

Hello everyone, i have a 2005 Polaris Sportsman 500 HO, and finally have the time and money to restore it, and give it some power. I am honestly looking to make as much power as possible, and am fine with the reliability drawbacks, and am going to switch to E85 fuel. I wanted to know what mods are out there, im looking for a good big bore, cam, carb, i have to get a new bottom and top end, so i could get a stroker kit if there is one avialable. I have tried to find these mods with no success, let me know if you guys know of any good mods.

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FPD218

· #2 · Feb 14, 2022

Twin Turbo's and afterburner.

PURE GENIUS - we need to get him a job in the engineering dept. at Polaris. (latebird)
FPD218, you should be on the Polaris design/build consult team. You have some good info you're passing on. (plumberwl5)
5X ATV OF THE MONTH WINNER. ***** OF ALL THE PATHS IN LIFE YOU TAKE, MAKE SURE A FEW OF THEM ARE ON DIRT!
2019 Sportsman 850 SP Premium, Removed all Warning Decals, 3500# Polaris Winch W/Synthetic Rope, Winch Stopper Cable Line Saver, Garmin GPS176C, Ram Mount, Polaris Rear View Mirrors, 4" Front Rack Extender, ATV-GURU.COM Front and Rear Bumpers, 2" Receiver in Front Bumper, Kenda K587 HTR Bear Claws 26X9X14 & 26X11X14, Rear LED work lights/strobes, Polaris Lock & Ride Rear Storage Box, Ultimate Series Windshield Fairing, Mid & Low Height Windshield, Center LED Brake/Tail Light, HighLifter Springs, Garage Products Bushings, added Left Rear brake caliper. EBC Brake Pads.

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Reactions: 1

TheNotSoMiniMiniMechanic

Discussion Starter · #3 · Feb 14, 2022

FPD218 said:
Twin Turbo's and afterburner.

I was thinking of calling up Elon and getting ahold of one of his rockets and welding that straight to the frame.

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Connor_Polaris

· #4 · Feb 14, 2022

some places peoples brains go lmao

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polman500

· #5 · Feb 14, 2022

E85? Why?
It'll destroy the fuel system components, collect tons of water in an open fuel system like your Sportsman has and I'm not sure how you'd jet the carb to correctly mix a fuel that can vary anywhere from 51% to 85% alcohol depending on geographic location and season.
Keep us posted on how this all works out for you.

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latebird

· #6 · Feb 14, 2022

If you are looking for more power, E85 or E100 is the wrong way to go - you need a higher BTU/lb fuel not less. Alcohol has about 1/3 less BTU's per pound than gasoline, so fuel economy and power output suffer. Also, you will need a steel fuel tank with about 2/3 more capacity to go the same distance as the OEM tank full of gasoline. You will need steel or copper fuel lines and a carburetor with no rubber parts used in it's construction. You will need to replace the carb holder (rubber) with an aluminum holder. The carb should be a flange mount with a paper gasket and to extract the same amount of HP from the engine using alcohol, it should be super charged or the compression raised to about 250 PSI static (cranking) pressure.

But the project will be fun and you will learn so much about engine building that you will swear off being an an IC engine engineer.

Research the project before starting it to find out exactly what the end result will be.

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Mike_B

· #7 · Feb 14, 2022

Y'all are crushing his dreams.

The first thing you should tell him is that" Sportsman 500" and "serious power " don't belong in the same sentence

You could increase output by 20% and still be under 40hp.

Sent from my SM-G970U using Tapatalk

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TheNotSoMiniMiniMechanic

Discussion Starter · #8 · Feb 14, 2022

Mike_B said:
Y'all are crushing his dreams.

The first thing you should tell him is that" Sportsman 500" and "serious power " don't belong in the same sentence

You could increase output by 20% and still be under 40hp.

Sent from my SM-G970U using Tapatalk

I'm more talking about in comparison to stock power, and anyways, there's a guy who makes a stroker kit that someone told me adds 15 or so hp, without any other mods, so considering my budget for this is quite high, I think I've got a good shot at making some power. And worst case, I'll call up Elon and strap a friggin rocket to the back.