Sportsman 700 stroked to 800cc

Rebuilding a Polaris sportsman 700 engine with an 800 crank and pistons.

[@philtarrant4438]

nicely done ...

[@deaconhairco5015]

Great video thank you

[@erikabrown3501]

Hi there I'm about to do a 800 swap into a 02 carb got to use the carb head did you use the 700 head gasket or a 800 one they look the same but different part numbers thanks

[@jagersgarage490]

I'm going to say I used the 800 gasket but dont know for sure it came with the 800 crank/rebuild kit I bought

[@Timmmmayg4787]

I'm doing this exact build. Gota 2002 sportsman and ordered a hot rods rebuild kit for an 800. Mine didnt come with the balancer journal bearings. Did yours? Also I'm finding the nut for my flywheel is different. Was that the same for you?

[@jagersgarage490]

From what I recall the bearings were separate and the fkywhee l nut was left hand thread but that was several years ago so I can't be sure.

[@Timmmmayg4787]

@@jagersgarage490 wow thank you for the reply. I will continue with my build and see what I come up with.

[@nismojuan]

How has the motor been running? Any issues the the balance shaft?

[@jagersgarage490]

The engine is running good it actually runs smoother than the 500 it replaced. I am still working on the carburetor jetting. I've been really busy lately but hope to have a video of it running and what it took to get it installed in the next week or so.

[@nismojuan]

Jagers Garage That's good. I was actually thinking of doing this but I couldn't find anything online or KZbin about doing this. It'll be great to see future videos

[@brandongodwin2539]

About to order the same parts literally today. I'm doing this to an 03 sportsman 700 (carburated) and ordering parts from an 05 sportsman 800 (efi). Same swap your doing, this should work, right? Or is my 03 model going to be different?

[@jagersgarage490]

Should work mine was also a carburated 700 and all the parts I ordered were for an efi 800.

[@brandongodwin2539]

Jagers Garage so I've ordered everything. I'm unsure of what to expect with the tuning situation. Did you have to rejet everything? Or replace to a larger carb? Any input on what worked for you would be great!

[@jagersgarage490]

Brandon Godwin only thing I have changed is the main jet it is currently a 142.5. Yours will very depending on your elevation. Most likely you will need to go smaller so just keep trying smaller ones till your plugs are golden brown.

[@brandongodwin2539]

@@jagersgarage490 okay well last year I completed the swap and could never get the engine to fire. I double checked timing and spark. Both were good so I gave up for a while. I'm back at it again and found the problem to be zero compression in both cylinders. Any ideas? I followed your video perfectly, what would be causing this I wonder?

[@jagersgarage490]

@@brandongodwin2539 something in the valve train could be the cam timing is off, lifters going flat

[@marklaughlin1068]

After doing this mine will start and then die it’s an efi do these have to be retuned

[@jagersgarage490]

If it starts the dies I think there is something else going on. It may need a tune will have to read the plugs but the change should not be enough for it to not run.

[@marklaughlin1068]

Jagers Garage got it going not sure if it was the starter assembly sticking in or the crankshaft sensor wires not getting good continuity Thanks

[@jamiejohnson2068]

Do you have a part 1 video?

[@jagersgarage490]

Jamie Johnson no sorry I did not do a tear down or removal video. Do you have a specific question I might be able to answer for you?

[@jamiejohnson2068]

Yes it's not the crank gear or cam or oil pump gear it's a key way gear near cam gear I can't get loose

[@jamiejohnson2068]

Think it's the only key way gear near the oil pump gear I did remove cam gear but this one seems stubborn

[@jagersgarage490]

Jamie Johnson from what you describe it would be the counter balancer gear I used a harmonic balancer/steering wheel puller. You can get one at most any auto parts store some at just $20.

[@jamiejohnson2068]

Thanks for the help yep that's the gear

[@green_03_silverado14]

This an 800 head to stroke this?

[@jagersgarage490]

I used the 700 head.

[@green_03_silverado14]

So really all it is. Is grind down balance shaft, 800 crank and 700 pistons?

[@green_03_silverado14]

I own a 03 Polaris sportsman 600 twin same style of engine. Wondering what all it will take to build it up. I notcied the 600 is 76.5 and 65 bore amd stroke compared to the 700s 80 and 68

[@jagersgarage490]

@@green_03_silverado14 800 crank and pistons.

[@crazyspeakerpro9584]

@@jagersgarage490 how much would I have to pay you for me to send my 700 engine to do this on it lol if that were to happen😂