I have a 1997 Polaris Sport with a 440 fan cooled engine. What kind of top speed should I be getting out of it? When I ride it the fastest it will go is about 65 mph. I’m a big guy, about 190 pounds, but I think it should go faster. What kind of mods would help me get even more power and speed out of it?
On the ice we can get an XCF (with the same 440 fan engine) to show 76-77 mph on the speedo. The first place I would start looking would be in the clutching; are the clutches shifting all the way out? Verify all of the basic clutch adjustments such as the alignment & belt deflection. Take apart the secondary and verify that the spring is at position B-2, as some of the ’97 Sports were set at B-3 which wouldn’t allow the clutches to shift out completely.
Want to go faster? Would you believe that you can drop on a set of 1985 440 cylinders (Polaris part # 3083441) that have a different port height and really make power at 7200 rpm, in comparison to the 6800 rpm that your 440 runs at now. Of course, you’ll have to re-carb and re-clutch the package, but you’ll gain 4-5 hp in the process, and that’s a lot for a fan cooled engine! I know of a few XCFs that are running this set-up that really scream. It’s not the least expensive route, but it works.