CBR600 f4 motor swap, Polaris sportsman 500 ho 

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

If I get the chance, I’ll be there. 🤙

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.

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!

When I have it apart next I will shoot a video. I’ll show the trans input shaft in pieces to show how I put it together.

Is that transmission video up

It’s hard mounted to the frame without rubber mounts, no vibration really probably because of the soft tyres and suspension. I’ve used the engine to stiffen up the frame and it works perfectly. I used 5mm and 6mm steel plate, made each bracket as I got to it from cardboard and then traced onto the steel plate.

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.

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?

@@malooooooooo8 I want too use something like gsxr 400 or other bikes similar cc something with more power cuz my motor broke and i can't find the same 300cc motor and i want too ask you if you changed transmission cuz my kymco has automatic with 1 speed it goes no more gears polaris has the same trans?

@@malooooooooo8 But im not mechanical i cant do it by myself

@@petrospetros3144 hey mate, I’m not sure how your machine will have to be chopped to fit a different motor as I haven’t done a kymco. From what I can see on the googles your transmission is similar to a Polaris 90 quad or a gy6 scooter. Trans in my quad has hi/low and reverse gears aswell as the cbr600 transmission. Work out what motor you are going to use for the swap and then you will have a better idea of what you can do to get it to work. Atm I’m swapping a cb400 vtec into an old rusted out trx300 and I’ll have to chop out all the rear swing arm and diff and make up a new swing arm to suit the chain drive. Your project will end up sorta the same I’m thinking. I’d like to help with your build but with me here and you there it may be somewhat hard.

@@malooooooooo8 is safe to have this big motocycle motor on a utility atv like kymco and polaris? cuz my father tells me this will be super dangerous