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Polaris IQ 440 trail conversions
(This page is updated every few days so check back often. Free shipping on aftermarket parts over $100 total)
Quick Links: Basic Trail Conversion Parts  Body/Chassis  Drive Train  Exhaust  Fuel/Intake  Manuals  Mountain       
Oil Injection  Steering/Controls  Storage  Suspension    
440 Notes  600HO Notes  600R Notes  Cautions/Troubleshooting   Tech Support
 

We convert Polaris IQ 440 & 600 race sleds to aggressive trail sleds that can still hit the jumps. We do all the necessary conversions and then some. These pages contain all the items you need for your conversion plus some great accessories.  Please use the tech notes as a reference before calling with any tech questions. If you do your conversion right your new ride may be the most fun you have ever had on a sled. We have countless hours in research and development to bring all of this information to you. All we ask in return is that you make your purchases with us so we can continue to expand this site.

 
                                     NECESSARY ITEMS
Large Polaris fuel tank with pickup, hose and fitting $250(this is not the kit)
+ Shipping
(shipping is initially charged $50 in the USA-covers most areas. Canada is usually around $110 USPS Priority mail)
Large Polaris IQ fuel tank kit $290
Pure Polaris large capacity fuel tank 8.8 gallons-Fits Polaris IQ race sleds. Tank comes with the fuel pickup, hose and fitting installed, mounting hardware, tank bra, tank pad, and instructions. THESE SELL OUT FREQUENTLY! (Sometimes for months) In stock as of 12-12-09
 + Shipping
(shipping is initially charged $50 in the USA-covers most areas. Canada is usually around $110 USPS Priority mail)
Polaris tank mounting pan head screws  $2.00 a pair (recommended by us)
These are low profile and your studs wont rip out of your track if they hit them. Can also be used to replace the 6 rear bumper bolts. The stock bolts can tear into the track.
Polaris tank mounting studs & nut kit  $10.00 a set
These are used on the 600RR and make mounting the tank much easier.

Trail Tank 10.5 Gallon fuel tank $344.99 + Shipping
(UPS shipping is initially charged $50 in the USA-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $110 USPS Priority mail)
Fits 2005 – present Polaris IQR/600RR
10.5 USG /40 L capacity
You will need to use your stock fuel cap, fuel line fitting, grommet, pickup and pickup hose.
Options: fuel gauge, mid-tank access plate, tail light relocation kit
Available in clear and black (black will take longer to get)
Comes with all necessary mounting hardware and Installation Instructions
Both colors are shipping now.
Color

Trail Tank 10.5 Gallon fuel tank with pickup hose $362.99 + Shipping
(UPS shipping is initially charged $50 in the USA-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $110 USPS Priority mail)
Fits 2005 – present Polaris IQR/600RR
10.5 USG /40 L capacity
You will need to use your stock fuel cap, fuel line fitting, grommet, and pickup.
Options: fuel gauge, mid-tank access plate, tail light relocation kit
Available in clear and black (black will take longer to get)
Comes with all necessary mounting hardware and Installation Instructions
Both colors are shipping now.
Color

Trail Tank 10.5 Gallon fuel tank kit with complete fuel pick up $415 + Shipping
(UPS shipping is initially charged $50 in the USA-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $110 USPS Priority mail)
Fits 2005 – present Polaris IQR/600RR
10.5 USG /40 L capacity
You will need to use your stock fuel cap.
Fuel line fitting, grommet, pickup and pickup hose are all included on this kit.
Options: fuel gauge, mid-tank access plate, tail light relocation kit
Available in clear and black (black will take longer to get)
Comes with all necessary mounting hardware and Installation Instructions
Both colors are shipping now.
Color
Trail Tank pick up hose for Trail Tank tank  $17.44 available now
For use with the 10.5 gallon Trail Tanks.
In tank pick up filter #5 for Trail Tank tank  $27.70
For use with fuel tank hose.
In tank hose clamp #6 for Trail Tank tank  $7.80pr
For use with fuel tank hose.
Fuel tank fitting and grommet #7 and #9 for Trail Tank tank  $18.39
For use the Trail Tank fuel tank.
Polaris 440 IQ 92 octane trail head kit $162.92
Fits 05-07 Polaris IQ 440 race sleds. This low compression trail head kit includes the 7 O-rings and 1 gasket needed to do the job. It will come with S47H weights and an instruction sheet (from '02) but please review our tech notes before using either. Timing box should be set at G and left there. ('06+ sleds will also need a timing box-sold separately below)
440 Trail Carb Jet Needles $27.92 a pair
These remove the lean spot in the midrange and help prevent mid throttle burn downs 

Polaris supplement rear heat exchanger $129.99
Supplement rear heat exchanger/cooler IQ 440-600 racers.  Mounts on the rear of the tunnel. Without this your engine will be sluggish just after racing down the lake-like when your lining up for race #2. Installation instructions here
Timing control box $116.37
Timing control box. Advances or retards the timing up to 4 degrees. Required for 440 trail conversions or you will have pre-ignition. Run it on position G.   
EXTRA ITEMS
Polaris IQ 440 piston kit  $145.00ea (order 2 for both cylinders)
Polaris piston kit. Includes 1 piston, 2 rings, 1 pin, and 2 circlips Fits 02-07 Polaris 440 race sleds.
Cylinder base gasket 440/600HO  $9.23ea (order 2 for both cylinders)
Maxima Quick 2 Mix oil bottle $6.25
The Maxima Quick 2 Mix™ bottle has been calibrated to give you the ability to accurately mix in ratios of 24:1 to 100:1. Holds 20oz of oil and you can fit 2 of these in the Gears storage bag below nice and snug.
Champion Spark Plugs for 440-600 '05-'10 Race sleds $5.80pr
These burn a little hotter on the low end and the same temp on the high end. You will have less loading up and fouling with this plug. Stock plug sold in pairs.
  



Click to enlarge

 5.375" wheel kit with your choice of color (Includes 1ea of # 29-34) $46.06each
We recommend adding 4 extra outer bogie wheels for trail riding. This kit has 5.375" wheels with a 6205 bearing for use with Edge style/Garland profile 23 Hyfax. Note: Some wheels may come with plastic spacers that will need to be tapped out prior to installation.
Color

1 Wheel and 1 mount-no hardware (Includes 1ea of # 32 & 33) $37.81

Color



Click to enlarge

 5.62" wheel kit with your choice of color (Includes 1ea of # 29-34) $46.06each
We recommend adding 4 extra outer bogie wheels for trail riding. This kit has 5.62" wheels with a 6004 bearing for use with stock IQ/Garland profile 24 Hyfax (standard). Note: Some wheels may come with plastic spacers that will need to be tapped out prior to installation.
Color

1 Wheel and 1 mount-no hardware (Includes 1ea of # 32 & 33) $37.81

Color
5.375" inner wheel kits with spacers $82.00pr  
We recommend one pair of these to protect your Edge/Garland profile 23 hyfax and front track shock. These inner wheels have a hole drilled into them so that you can easily remove your front track shock bolt
5.62" inner wheel kits with spacers $82.00pr  
We recommend one pair of these to protect your IQ/Garland profile 24 hyfax and front track shock. These inner wheels have a hole drilled into them so that you can easily remove your front track shock bolt
Aftermarket Colored Edge/Profile 23 Hifax 61"   $45.90pr (cut to length, will fit most long tracks) These should be used with 5.35" and 5.375" wheels
Color
Aftermarket Colored IQ/Profile 24 Hifax 61"   $45.90pr (cut to length, will fit most long tracks) These are 1/8" thicker than profile 23 and should be used with 5.62" wheels
Color
Polaris IQ race chassis heavy duty cover $159.95
Polaris now has this new heavy duty cover for all IQ race chassis and the 600rr. This is the best cover yet. Two straps attach it to the spindles, four straps attach it to the skid and one going across between the bars and windshield to keep it tight. It has padding built in for the handlebars and along the foot well grip strips. It also has a zippered door to access the gas tank. Well worth the money
Handguards-block the wind and any snow roost just in case you get temporarily passed.
Polaris handguards are available here
Sportech handguards are available here
Sportech Cobra 9" white windshield $84.95
 Fits Polaris IQ race sleds + 600RR.  Installs in minutes.
Sportech Cobra 9" matte black windshield $84.95
 Fits Polaris IQ race sleds + 600RR.  Installs in minutes.
Powermadd 12" matte black windshield $89.95
 Fits Polaris IQ race sleds + 600RR.  Installs in minutes.

Polaris 9" Dragon windshield. Fits all Polaris IQ race sleds + 600RR.  
These sold out and are no longer available from Polaris.

Outerwears pre-filter $17.95
There is no real filter system on these sleds so this Outerwears pre-filter is a must. Click on the 2nd picture to see the dirt we filtered out in only one 300 yard run. Fits over intake horn.
Works on IQ 440 trail converted sleds. (Not for 600's or higher, on those use a fine screen and a clamp around the horn) 
 
Polaris IQ hood foam kit $189
Hood foam is added to reduce engine noise. This helps a lot!  This the full kit with foil and fiber from the 600RR. Fits all Polaris IQ race sleds + 600RR. 
 
Skinz knee pads $39.99
Console Knee pads, a must, from Skinz for $39.99. They Velcro on and protect your knees all day. They feel great. Fits all Polaris IQ race sleds + 600RR.  Installs in minutes.
Adjustable Toe Hooks $29.99pr
Adjustable Toe Hooks. Can be mounted facing in or out of the footwell. Adjust up or down 1". Comes with all hardware. Fits all Polaris IQ race sleds + 600RR.  Installs in minutes.
 
Skinz slick seat wrap $199.95
 Fits Polaris IQ race sleds + 600RR.(special order) 
Skinz sticky gripper seat wrap $224.95
 Fits Polaris IQ race sleds + 600RR.(special order) 
Polaris flexible hard plastic race snow flap $67.48
 Came stock on most '06-'09's
Many compatible RMK colored accessories can be purchased here.

Skinz rear bumper $139.99
Skinz new rear bumpers available in 3 colors. Fits Polaris IQ race sleds + 600RR. Installs in minutes. This is a stocking item however this time of year they sell out frequently. Black is usually available. Orders for silver or red are currently taking 2-4 weeks to get.
Color

Tech notes, jetting, clutching and more
Quick Links: Trail Conversion Parts   Mountain   Body/Chassis   Suspension   Drive Train   Exhaust   Fuel/Intake  
Oil Injection   Steering/Controls   Manuals   440 Notes  600HO Notes  600R Notes  Cautions/Troubleshooting   Tech Support

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