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| Polaris Sportsman 800 Mega Power Pipe Development |
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The new Fuel injected Polaris Sportsman 800 presented a new challenge when we considered developing a
new exhaust system. In stock form the Polaris Sportsman 800 engine provides a respectable 54.8 HP at 6000 RPM, but the power dips
very sharply behind the peak to only 45.2 HP at 6200 RPM. Maximum torque is 51.8 lb/ft at 4800 RPM. The stock system is unique
because the header pipes combines into one pipe, which feeds into the right hand muffler, with a branch pipe feeding to a second
muffler on the left side. This is not a true twin system since the cylinders do not feed a silencer each. The reason became obvious
when we tried a true twin system with each pipe feeding its own muffler. The result was good bottom end torque, but a large loss of
power at top end because the individual pipes became so long that they were totally out of tune at higher RPM.
The best set-up on the Polaris Sportsman 800 is a single Mega Power silencer with a large diameter core mounted to the stock header
pipe. This resulted in a peak power of 57.2 HP at 6000 RPM, but still pulling strong with 54 HP at 6200 RPM where the stocker had
fallen off to 45.2 HP. The big reward comes further down the power band where the single Mega Power pipe provides 4.8 HP more at
5000 RPM with a 5.2 lb/ft increase in torque. The torque peaks at 56.8 lb/ft at 4800 RPM but still provides 56.5 lb/ft at 3600 RPM
where the stock torque had fallen to 49 lb/ft. This is a big 7.5 lb/ft increase in torque in the lower RPM band and makes this
combination a real stump puller.
There is no need to calibrate the fuel injection unit, because Polaris left it on the rich side, and this works well with the extra power of the pipe.
To prove the pulling potential of this new combination, Chuck Grimm entered his Mega Power piped Polaris Sportsman 800 with our
aggressive clutch kit in the May 1st Monkey Butt pulling contest, and pulled the full distance 3 times. The 1400 lbs. Pulling
trailer could not put enough load on to stop him. Chuck reports a good increase in top end speed and awesome power in the midrange.
Switching to the single pipe saves 14 lbs. in weight and the silencer comes standard with the quiet core, while a 4" Supertrapp
forestry service approved spark arrestor kit is available.
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| Part Number |
Item Description |
Price |
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| PAT 30095 |
Mega Power Pipe Sportsman 800 (05-07) |
399.00 |
| PAT 96053-SC |
Mega Power Pipe Sportsman 800 (11-14) Silver Ceramic |
399.00 |
| PAT 96053-BC |
Mega Power Pipe Sportsman 800 (11-14) Black Ceramic |
399.00 |
| PAT 96028 |
Mega Power Pipe Sportsman 800 (08-10) |
399.00 |
| PAT 96053 |
Mega Power Pipe Sportsman 800 (11-14) |
399.00 |
| PAT 50100 |
Spark Arrestor |
129.00 |
| PAT 50006 |
Shield (Use with Spark Arrestor) |
49.00 |
| ATC 30071 |
Clutch Kit, Sportsman 800/RZR 800 |
118.00 |
| ACA 6026 |
TFI Tuner |
249.00 |
| ATP 12995 |
700/800 Twin Head Porting |
399.00 |
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