Category Archives: ATV Performance Modifications

Barker’s Exhaust Slip On for Sportsman XP 550/850

I finally made it to the dyno with the first ever Barker’s slip on for the Sportsman XP’s. Like most slip on exhausts my expectations were low. I love the sound but didn’t expect the system to make any gains. I was wrong, this exhaust made 2HP and 1.5TQ. This was a stock 2009 Polaris Sportsman XP 850 with no other modifications other than a direct slip on swap, stock vs Barker’s. The air fuel ratio began to lean out but not to a dangerous level. This exhaust will benefit from a fuel controller and we expect it to make anywhere from 3-5hp. More testing to come in the future. This is just a prototype. Aside from the power gains this system is extremely high quality and will not fall apart like other systems which I have experienced myself. I will update this post in the future when we make it back to the dyno. On that note, here it is. An exhaust system with proven dyno results!!! Power gains were made across the board!!!
Barker's Performance Exhaust | ATV, UTV, Snowmobile, Motorcycle Exhaust ? Barker’s Performance

Converting a 89` Trail Boss 250 4X4 to a 4.7kw Yanmar DIESEL

As nice as a 2 stroke gasoline trail boss is, It`s not for me, I have been working on diesels for the past 5 years and they have been shown to be superior to gasoline in every way EXCEPT speed. No a 4.7kw diesel will not beat 7000+rpm the Polaris engine puts out, but I would like something with a little power. So I have started a conversion project on a 89` Trail boss 250 4X4, but I have never owned a ATV before :o. I have cleaned up and bed-coated the frame and completely restored the body of this atv that I picked up for around 400$ with a non-running 2-stroke engine, I have gotten it running as of now and I would like to sell it. It runs fine but the carb needs adjustment which I have no clue how to do. So I put it up for sale on cl for 250$. So below I will list my problems and progress on the conversion, for you experts to advise a atv noob like me.

Steering Stem handlebar mount broke?

Had anyone experienced this failure?

I was out riding on some really rocky trails and my steering suddenly felt really strange. It wasn’t obvious at first but about halfway home I realized that the right side of my handlebar was unattached [emoji51]. By forcing the right side down the whole time I was trying to get home (~10 mi.) I was able to make it back. When I finally got home and took the pod apart, the picture is what I found – the Wildman at the top of the steering stem had partially cracked away from the stem.
I’m planning to weld it back in place and put a reinforcement bracket behind it so I don’t have to replace the entire steering stem.
Has anyone got any advice or comments?
For what it’s worth, it’s 2001 Sportsman 500 HO.

Sent from my SM-G920V using Tapatalk

Steering Stem handlebar mount broke?

Had anyone experienced this failure?

I was out riding on some really rocky trails and my steering suddenly felt really strange. It wasn’t obvious at first but about halfway home I realized that the right side of my handlebar was unattached [emoji51]. By forcing the right side down the whole time I was trying to get home (~10 mi.) I was able to make it back. When I finally got home and took the pod apart, the picture is what I found – the Wildman at the top of the steering stem had partially cracked away from the stem.
I’m planning to weld it back in place and put a reinforcement bracket behind it so I don’t have to replace the entire steering stem.
Has anyone got any advice or comments?
For what it’s worth, it’s 2001 Sportsman 500 HO.

Sent from my SM-G920V using Tapatalk

Winch question

I have a 2005 sportsman 500. Putting a winch on it now. I’m putting this bracket on.
2005-2010 Sportsman 500 Winch Mount – Winch Mounts – POLARIS – SPORTSMAN – Sportsman 500 – 2005-2010 Sportsman 500 – KFI ATV Winch, Mounts and Accessories
I found this winch on Amazon. Done a little research.

Pretty good price for the whole set-up.
Is this winch too big to fit the bracket? Superwinch website says its for an ATV.
The Terra 25 is only 9 bucks less so I figure bigger is better. At least until it doesn’t fit. If anyone has tried and failed I would like to know before I buy and have to return.
Thanks