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Polaris IQ 440/600 trail conversions
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 $268
(this is not the kit-it's below)

Polaris large capacity fuel tank 8.8 gallons-Fits Polaris IQ race sleds. Tank comes with the fuel pickup, hose and fitting installed. You must remove the nuts riveted to the seat skirt to mount. You will need to get hardware for mounting. See below.  We strongly recommend the pan head mounting screws.
+ Shipping
(shipping is initially charged $60 in the USA
-covers most areas. Canada is usually around $120 USPS Priority mail. All tanks will require a signature for delivery)
Large Polaris IQ fuel tank kit $320
Fuel tank with pickup, hose, fitting, bra, padding and instructions.
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. You must remove the nuts riveted to the seat skirt to mount. We strongly recommend the pan head mounting screws.
+ Shipping
(shipping is initially charged $60 in the USA
-covers most areas. Canada is usually around $120 USPS Priority mail)
Polaris fuel 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  $12.00 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 $65 in the USA
-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $120 USPS Priority mail. All tanks will require a signature for delivery)
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
Fuel gauge is standard/included and installed on black tank only.
Tank was made to fit over the top of our heat exchanger.
Comes with all necessary mounting hardware and Installation Instructions

Color

Trail Tank 10.5 Gallon fuel tank with pickup hose $362.99 + Shipping
(UPS shipping is initially charged $65 in the USA-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $120 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.
Fuel gauge is standard/included and installed on black tank only.
Tank was made to fit over the top of our heat exchanger.
Comes with all necessary mounting hardware and Installation Instructions

Color

Trail Tank 10.5 Gallon fuel tank kit with complete fuel pick up $415 + Shipping
(UPS shipping is initially charged $65 in the USA
-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $120 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
Fuel gauge is standard/included and installed on black tank only.
Tank was made to fit over the top of our heat exchanger.
Comes with all necessary mounting hardware and Installation Instructions

Color

Trail Tank 10.5 Gallon fuel tank kit with complete fuel pick up and tail light relocation kit $425 + Shipping
(UPS shipping is initially charged $65 in the USA
-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $120 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
Fuel gauge is standard/included and installed on black tank only.
Tank was made to fit over the top of our heat exchanger.
Comes with all necessary mounting hardware and Installation Instructions

Color

Trail Tank 12.5 Gallon fuel tank kit with complete fuel pick up and tail light relocation kit $445 + Shipping
(UPS shipping is initially charged $65 in the USA
-covers most areas. Parcel Post/Cheaper shipping is available if you call us.  Canada is usually around $120 USPS Priority mail)
Fits 2005 – present Polaris IQR's but NOT for 600RR (crossover hoses are in the way)
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
Fuel gauge is standard/included and installed on black tank only.
Tank was made to fit over the top of our heat exchanger.
Comes with all necessary mounting hardware and Installation Instructions

Color
Trail Tank pick up hose for Trail Tank tank  $17.44 available now
For use with the 10.5 gallon Trail Tanks.
Trail Tank pick up hose for Trail Tank tank  $19.95 available now
For use with the 12.5 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  $22
For use with the Trail Tank fuel tank.
Trail Tank Fuel Gauge  $35.99
For use with the Trail Tank fuel tank. Requires drilling a hole in the tank and one in the console so you can see it.
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 (S49H on the newer ones) 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)
 
Polaris '08 600R stock head $200
Will run on 92 octane.

 
Polaris '09-'12 600R stock head $224.94
Will run on 92 octane.  

440 Trail Carb Jet Needles $32 a pair
These remove the lean spot in the midrange and help prevent mid throttle burn downs 

Polaris supplement rear heat exchanger $179
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. All trail converted IQ's should run an extra cooler. Its stock on the 600RR so you know how Polaris feels about it.
Installation instructions here
Timing control box $124.35
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  $160.00ea (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/600RR  $11ea
stock thickness (order 2 for both cylinders)
Cylinder base gasket for '08 600R  $11ea
stock thickness (order 2 for both cylinders)

Cylinder base gasket for '09-current 600R  $6ea
stock thickness (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 clutch cover storage bag nice and snug.
Champion Spark Plugs for 440-600 Race sleds $5.80pr
Stock plug, sold in pairs. These burn a little hotter on the low end and the same temp on the high end than normal plugs. You will have less loading up and fouling with this plug.
 
NGK Spark Plugs for 440-600 Race sleds $5.80pr
 



Click to enlarge

IQR 5.62" Outer wheel kit with your choice of color (Includes 1ea of # 29-34) $54 each (red is $10 additional)
We recommend adding 4 extra outer bogie wheels for trail riding. This kit has one 5.62" wheel with a 6205 or 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 Outer bogie wheel and 1 mount-no hardware (Includes 1ea of # 32 & 33) $39 (red is $10 additional)

Color


Mounting Pictures

'11-current spacer washers for use with 1, 5.62" outer wheel kit $3.20 Spaces over front track shock reservoir. You only need 1 kit per sled. Use 3 between resi and rail on both bolts and 2 on the long top bolt on the outside before the spring washer and wheel.
5.62" inner wheel kits with spacers NOW $62.00pr 
We recommend one pair of these to protect your stock IQ or Garland profile 24 hyfax and front track shock. We recommend adding these wheels first. These inner wheels have a hole drilled into them so that you can easily remove your front track shock bolt. May not work on the 2011 and newer without changing the shock reservoir and hose connectors.
Aftermarket Colored stock IQ Profile 24 Hifax,
Black or White $60pr, Colors $76pr

All colors 64" long except white, 61"
(
needs cut to length, will fit most long tracks) Same profile as stock Hifax. For use with stock 5.62" wheels
Color
Polaris IQ race chassis heavy duty cover $189.99
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. Currently NLA
Powermadd 12" matte black windshield $89.95
Fits Polaris IQ race sleds + 600RR.  Installs in minutes.
Powermadd 14" Tint with black fade windshield $96.95
Fits Polaris IQ race sleds + 600RR.  Installs in minutes.
NEW HIGH FLOW pre-filter for 440 and 600's  $20.95
There is no real filter system on the IQ race sled so this pre-filter is a must.  Fits over intake horn. Works on the 440's and 600's as well. We recommend running a bead of silicon around the headlights to keep powdery snow from building up on top of the pre-filter and causing a bog. For completely trail converted sleds only.
Color
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.  Special Order.
 
Skinz knee pads $59.95
Console Knee pads, a must, from Skinz. 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 $35.99pr
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 $73
Came stock on most '06-'09's. Fits all IQR's
Polaris NEW 2011 Pro RMK Snow Flap $30
will fit the IQ race chassis
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:
Basic Trail Conversion Parts   Body/Chassis   Drive Train   Electrical   Exhaust   Fuel/Intake   Manuals  Mountain   OEM Parts   Oil Injection   Steering/Controls   Storage   Suspension   Trail Tracks/Traction
Quick Reference  
440 Notes   600RR/HO Notes   600R Notes   Cautions/Troubleshooting   Tech Support  

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