Just a generic 520 sprocket 11t. I had to thin it down to suit 525 moto chain and I had a spline cut into it. It then slips onto the shaft that was inside the original Polaris driven clutch, then that slips onto the gearbox as it did before when it was a driven clutch. Sounds complicated/confusing but it’s not at all after you see how it goes together. I’m looking into getting a roll ring chain tensioner atm as I have melted a few chains off this thing due to tight chain radius and shitty chain tensioner design. I hope you go through and finish it, there are not many like this and it makes it a totally different monster. What motor are you using?

@@malooooooooo8 i got a wrecked yamaha mt09. so im using the 3cyl 900cc cp3 from it. id love to see your setup. do you happen to have any pics? did you use some type of pillow bearing at the end of the shaft to prevent it form snapping?

@@malooooooooo8 ive gotten like 4 sprockets now lol. havent had much luck. they wanna charge me $500 to cut the splines into the ones i have... id love to hear more on how you got it done

@@alfredoc1283 I literally went down to the machine shop with the blank gear and the shaft from the driven clutch, came back a week or two later and he stung me 100 bucks. It will be a 1 off for him to make the cutter and set up for just 1 spline but that’s seems pricey. Where abouts are you?

@@malooooooooo8 miami, fl. luckily i have a machinist friend who just made one for me. ill probably post some vids in my channel later. ill send you the link in case ya wanna see it!

Low down torque is not as good as the 500 but if it’s revving over 4000 in high range you’re going over whatever you want to take it over. Low range tho I can basically idol through up and over whatever you dare point it at. Thing revs out to 13 or 14k.

I may do that as a few others have also asked the same thing. I’ll show you in a video as I may lose you in my description if I were to type it. I use all the gears, sometimes skip first if it’s flat ground on the take off . The gears are really short due to the reduction in the Polaris gearbox something around 15:1 high and 26:1 low. The bike weighs in at about 300-350 kg so she is not a light weight. I’ve had it going up some fkn beastly angles up in the vic high country.

I didn't realize the reduction was so much. Figured output shaft speed could be determined just using stock rpm of the polaris and multiply by 2. Then the lack of torque would be made up through rpm. It'd take a bunch of shifting but usable. Super cool buuld

Cus I wanna do the same thing to my Polaris sportsman

Is it still a auto or did you change it to a manual gearbox

hey mate, it cost me a few hundred bucks coz i was given the quad for free and i grabbed a workmates old trackbike cheap and resold the frame. materials was all scrap metal from under the workbench etc.

@@twoommotors8823 its a manual now but im still running the polaris transmission for 4x4 rev low and high range.

@@malooooooooo8 All right cool

Cheers mate, she scoots along and hits the 75 mph limit on the speedo no probs but it pulls past that to about 80ish I’d say.

Cheers mate, I the cvt is gone and in its place I have 525 chain from the cbr going back to the trans input shaft, I had a gear cut to suit. The 500 was sorta made for it but the engine is a tight fit with the exhaust, front prop shaft and sump and no frame extension. The top frame rails were chopped and modified to bolt in items to clear the head and to get the motor back out. Torque is on the low end unless your over 5k rpm in high range but at the top end it’s mental. With current gearing and with low range it’s like I have a set of reduction gears in the trans and let’s it idol up some pretty steep shit. Cbr gearbox is untouched but I would like to install a recluse clutch to free up my left hand on the hills. It feels awesome to smash through the gears on the tracks on this thing and keeps up with my mates on 4fiddy dirt bikes not a problem until we get the 40-50+ degree hills. That noise is the tensioner, at low speed its noisy but at high speed it’s like strait cut gears and I kinda like it now. Someday I’ll redesign that to suit bigger front and rear sprockets inside its own oil filled case so the chain can last a bit longer and make it quiet. If I get my hands on another dead quad I’ll do a cross plain 1k swap.

Hey mate, it cost me basically time and $400 or $500 in little bits like fuel system and machined parts. The quad itself was given to me free from a good mate and I got the doner cbr for 200, striped it and sold the frame for 200. The wheels where probably the most expensive at 800 bucks but that was paid with some tax return so I’ll call those free. The Polaris was pretty strait forward to put together but just looking at the rear end on your kymco thinking it might be a pain to mod a different engine in there without swapping the rear swing arm as the diff looks to be on the RHS. What engine are you thinking of using?

the stock Polaris speedo stops at 75mph and include the taller wheels I think it would be around the 130 plus kph, the Honda speedo is up near 280 kph. It likes to fishy at over 100kph on gravel road when you hold it open. The trans should hold if I treat it nice, clutch dumps and burnouts in reverse would be a killer for it eventually.

Cheers mate. Yes, all done with basic tools in my shed with acception of the spline and gear I had cut to suit the Polaris transmission. If you can, have a go at one yourself, absolute weapon of a quad. I’ll be taking it apart to do a few mods and repairs in a week. I’ll make a video showing what mods I made to fit the cbr motor.

That will be a fun little project, you keeping the 4x4?

Is that transmission video up

Yes, with a few mods it works similarly to n/a.

@@malooooooooo8 What kind of mod?

Mate, she has done alright so far with boost up to 15psi. Only thing I don’t like about it is neutral is at the very bottom and for that reason I’ll be putting this turbo kit on a 190 next. 👌

That sound is the steel chain roller I’m using to tension the chain and ur right, I’m having some new gears cut that are slightly larger so I can try to delete the tensioner. I’d use a MC plastic/rubber tensioner but the chain speed is so fast I don’t think it’ll cop that for long. Good thing is that noise sounds like strait cut gears when at speed.

Thanks mate, got the first rip in today, it flies.

Should have done this instead 😂👌

@@malooooooooo8 😂 i had it for 6 years probably put more money in fuel in it than what it was wort by about 5 fold, it got burned out and boring so i got a SantaCruz Hightower. It was the same color as yours too

Autis Medic nice bike to swap ur old quad for. Probably the same or more suspension travel on the Hightower as the sportsman. 👍

@@malooooooooo8 yeah it has like 6 inches in the front

Cooling isn’t a problem as the Polaris has a bigger radiator than the cbr, only problem I had was linking in the oil cooler because the Polaris radiator doesn’t have enough barbs on it. So I made some steel hardlines with the barbs to run to the oil cooler etc. I’ll find out how it’ll take a 45 degree heat this summer.

With the cb400 it went about 80-85km/h but now with the cbr600 it should smack 100 due to double the power of the cb and 1 extra tooth on the drive sprocket. Not the fastest top speed of say a banshee with the same motor I know but it runs through the Polaris trans and it’s ended up with a double gear reduction so it has enough torque to pull any hill that has traction. I’ll put a video up when we are out of lockdown “if ever” with the new cbr600. 👍

Hey mate, to get the motor in there I had to cut the top frame rails and modify to allow me to bolt them back on and to allow a 4 cylinder to fit in, had to make mounts and weld those to the frame. To get drive I disassembled the driven clutch and had a gear made to fit on the main clutch shaft and I run the motorbike chain directly into the Polaris trans. You need to use the smallest gears that will fit on the trans because of the double reduction you get from the motorbike and Polaris trans. 10t was the smallest I could run on the trans input shaft using 525 chain, 16t sprocket on engine. What motor you going to use? I’ve just jammed in a cbr600 f4 motor so it now has twice the power as it did in this video.

@@malooooooooo8 thats awesome and pretty much what I figured had to be done haha i have a 92 suzuki gsxr750 laying around that i can Frankenstein together lol just need to make sure the motor is worthwhile before I go through the effort. Also thinking of using a snowmobile engine instead since its already belt drive, just gotta find out if it can charge the battery cause I still want to use the original 4x4 system which requires power...

Travis Keller. a snow mobile engine would be a good option no doubt about it and I would think it would have a charge capability coz don't the snowmobiles have lights? We don't have very many of those in Australia for obvious reasons so I haven't had a chance to work on them and so don't know much about them. I'd love to get my hands on one someday. Make sure you put up a video when/if you go ahead with it coz it'll be a monster.

Cheers mate, no problem with tuning or having it pushing fuel back through the main jet coz I’m using a fuel reg and fuel pump. Stays about 1-2 psi above boost. Carby has all atmospheric ports linked to the pitot tube which is also 1-2 psi above boost. Im waiting for a new bike to put this motor into, had it running nice in my grom some time ago. Been waiting for this new bike since December 2019.

William Jenssen Hey mate, I cut the lower section off a small truck intercooler, capped off the tanks and fitted new pipes in the right spot. Done 🤙🏻

@@malooooooooo8 Nice! Did you just use a mig welder and angle grinder?

Yes that’s it mate, gave it a cleanup inside while I was there.

William Jenssen it’s a china copy of I think a vm26 mikuni from eBay.

@@malooooooooo8 awesome work brother! Once you get the carb tuned, it's just a matter of adjusting the power jet when temperature changes major or elevation. Pros and cons to both efi and carb. I love both! Most don't think a blow through carb on a single cylinder is possible, that's why I've stuck with it ha. Keep up the good work!

Turbocharged Could you tell me how you set up your Power jet?

gary jones I haven’t yet as it has no waste gate connected and the boost spikes, first I have to put the bike back to stock to pass rego then I’ll put this engine back in, but I was thinking something much bigger would be in order.

I am 98% complete, I’m tuning it in now. It pulls hard enough to slip the clutch in 2nd and 3rd gear. No wastegate fitted so it’s pushing near 14psi WOT.

So far I am, it runs like a normal 150 till it comes on boost, most times it will be a rich mix but I have had the odd sweet run and seen 12psi on the gauge. I have an aeromotive a1000 carb bypass reg on there now, I did try a malpassi with no luck still mucking around with it trying to dial the fuel system in 🤯, I lost interest for a while due to not knowing anybody doing a similar thing and couldn’t ask any of the million questions I had i my head.

@@malooooooooo8 i know how that feels. I ended up putting a whole new engine in mine because i was convinced i had done damage to the engine. Well done though figuring out all out. It not as simple as some think 👌👌

Motor is in and running but now to dial everything in, I’ll get the potato cam out soon and put up another vid . 🤙🏻

SRT480 Thanks bud, not wrong about trying to make it all fit in there will still need to trim some plastics but not to much at all. I’m going to use the stock efi pump in the tank with a fuel reg that drops the pressure down to carb friendly pressure but will raise the pressure to just over boost pressure as needed, haven’t got the reg yet but when it arrives i can let you know about it if ya like. A kind chap at a carby repair place nearby got onto it for me.

facebook.com/Joe.Schellbach/videos/10211868442486611/

im running blow through carbs on mine, requires a larger regulator that is more sensitive. this bike doesnt have the efi stock which is the biggest bummer but over all cost is much lower