Ever since the wife said no to a new toy, I have been trying to make my old ’98 500HO a little more acceptable to the style of my riding. Starting with sealing all the important areas, like the clutch cover, recoil cover etc. Also, I am snorkeling the old girl.

So I have a 1.5" pvc assembly run from the airbox, to the LF fender, and the intake on the clutch cover is running into the air box intake. Trying not to get in the way of plastics other than where they will protrude.

My 2 questions;

1: The exhaust on the clutch cover measures 2.75" ID. The OEM polaris "snorkel" is definitely restricting that flow. My question is what size ABS should one use? I would’ve liked to use 1.5" (cuz I live 45 mins from the closest home depot, and went tonight and bought $150 worth of 1.5" ABS fittings!) but really worry that I’ll be restricting it too much. I’ve already MELTED a clutch cover due to heat of the clutches. I don’t want to try that twice. I have a piece of 2" lying around that I kind of slid in, it fits and I’d make it work if others thought it necessary. Kinda like the idea of the lighter 1.5" stuff though.

2. Will 1.5" snorkel flow enough to feed this engine? The stock snorkel on the air box measures around 4.45sq/in and the 1.5" ABS measures 4.71sq/in on the inlets. The 1.5 is 3′ away though, with a couple bends. Also planning on installing a FST BBK 600 kit (as long as my never ending questions don’t make Mickey blacklist me LOL)

Trying to upload photos. Gonna try once more then it’ll have to wait until tomorry.