POLARIS 500 SCRAMBLER POWER DEVELOPMENTS,
FROM THE DYNO TO THE RACE TRACKS. |
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| We have had a lot of request for Dyno information on the Scrambler 500 Stage kits. The different Stages have been in development from 1997 to the present day. We did not want to mix
Dyno information from 5 years back with recent developments, so this spring we decided to run every stage
from Stock through Stage 5 back to back. This gives you a professional engineering evaluation of the power gains of each stage.
4X4 machines require good torque at lower RPM and all the mods deliver more torque in low and midrange than the stock machine.
Each Stage improves cylinder efficiency rather than gain power from high RPM. This in turn increases torque
and keeps the RPM close to stock levels to maintain reliability and prevent crank problems. Even Stage 5 pulls Max power at
6800 RPM only 200 RPM up from stock.
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All Stage kits can be purchased with the BILLET END CAP REBUILDABLE MEGAPHONE MUFFLER!
*** Call for pricing *** |
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 Stock: |
Max HP: 37.5 @ 6600 RPM, MAX Torque: 32.9 Ft/Lbs @ 5400 RPM |
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| Polaris claimed that the new 500 Scrambler would have as much power as their two stroke 400.
We found this to be true, the stock model dynoed out with 37.5 HP @ 6600 RPM and 32.9 Ft/Lbs @ 5400 RPM.
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 Stage 1: Parts |
Rebuildable Black Muffler - 7% Increase |
| Max HP: 40 @ 6600 RPM, MAX Torque: 33.7 Ft/Lbs @ 4800 RPM |
| Our Rebuildable Black Muffler has been in development since 1996 and has proven ideal for 4 Stroke ATV's
that need good bottom end and midrange performance. The Megaphone section creates a strong vacuum
signal across the power band, resulting in more HP, torque and quicker throttle response. Max power
with the Muffler increases to 40 HP @ 6600 RPM and Max torque increased to 33.7 Ft/Lbs @ 4800 RPM,
600 RPM lower than the stocker. This mod represents a 7% power gain over stock.
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| STAGE-1 / ITEM#.... PAT60000 / PRICE - $249.00 |
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 Stage 2: Parts |
42mm TMX Carb and Rebuildable Black Muffler - 12% Increase |
| Max HP: 42 @ 6600 RPM, MAX Torque: 35 Ft/Lbs @ 5400 RPM |
| The 42 TMX Carb has many advantages. Airflow is up 20% compared to the stock carb and throttle response is instant
instead of having to wait for vacuum to build up as on the stock CV carb. The TMX carb is not sensitive to Air box
vacuum like the stock carb and the box can be differently modified or the carb can be run with a straight Racing Filter
for better power. Test was run with stock air box. Max Power increased to 42 HP @ 6600 RPM and Max torque increased to
35 Ft/Lbs @ 5400 RPM. The Stage 2 Mods represent a 12% increase over Stock.
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| STAGE-2 / ITEM#.... PAK 5000 II / Call For Pricing |
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 Stage 3: Parts |
653 Longer Duration Cam, 42 TMX Carb and Rebuildable Black Muffler - 17% Increase |
| Max HP: 44 @ 6800 RPM, MAX Torque: 36.4 Ft/Lbs @ 5800 RPM |
| We tried several cams during development. Some produced more power, but at higher RPM's and
with a loss of bottom end torque. This cam has 10 degrees more duration with stock lift and
improves both midrange torque and top end power with only a 200 RPM increase. The Stage 3
combination produces Max HP of 44 HP @ 6800 RPM and a Max torque of 36.4 Ft/Lbs @ 5800 RPM.
This represents a 17% increase over stock.
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| STAGE-3 / ITEM#.... PAK 5000 III / Call For Pricing |
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 Stage 4: Parts |
653 Cam, 42 TMX Carb and Rebuildable Black Muffler - 20% Increase |
| Max HP: 45 @ 6600 RPM, MAX Torque: 37.3 Ft/Lbs @ 5600 RPM |
| Stock compression ratio is 10.2:1. Our piston increases the compression ratio to 11:1, which still permits you to use
premium 92 Octane pump gas. The improvement is stronger bottom end and midrange torque. The Stage 4 Mods give you 45 HP
@ 6600 RPM and 37.3 Ft/Lbs @ 5600 RPM. In comparison, a stock Polaris 700 Sportsman puts out 45 HP @ 6000 RPM. The 500
Scrambler is of course much lighter and has no trouble out performing the 700 with the Stage 4 kit mounted. This represents
a 20% increase over stock.
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| STAGE-4 / ITEM#.... PAK 5000 IV / Call For Pricing |
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 Stage 5: Parts |
Ported Head, 653 Cam, 42 TMX Carb and Rebuildable Black Muffler - 25% Increase |
| Max HP: 47 @ 6800 RPM, MAX Torque: 38.3 Ft/Lbs @ 5600 RPM |
| There is more power to be found by porting the head. Intake and exhaust ports are enlarged and valves unmasked. Total
power with the Stage 5 Mods is 47 HP @ 6800 RPM and Max torque is 38.3 Ft/Lbs @ 5600 RPM. This represents a 25% increase over stock.
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| STAGE-5 / ITEM#.... PAK 5000 V / Call For Pricing |
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