A few upgrades for the polaris 120

Mar 13, 2019
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"It's been a show", as my wife would say! The suspension geometry changed by moving the track on the driver ahead and it threw everything off. Had to redo the rails and move the top idler wheels. Also cut and moved the bulk head in towards the engine, but then it hit the valve cover. So messed with that for a day to get it just right.

My advice, sell, sell, SELLL and buy a 200 bahahahah

Bulk head cut and bent it. Had to weld it back up solid to keep the snow out.





here it was with the track rubbing



It's hard to tell from this picture but the idler wheels are move WAY back and down. They where origanally on the shaft that the top of the coil over is attached to. I am going to try and relocate the top of that coil over to the shaft with the wheels on it. It will work WAY better angled the other way.



We've only had it down the alley so far and I think it's going to work great. Geared back up to 2.3:1 (from 2:1) and that should give us 30mph Has better low end torque as the 5 tooth driver didn't seem to pull much power from the engine?? And it's been dang cold here. -30 this morning and that's the warmest it's been in weeks. I've been sledding but the kids can't handle it. The new Cold Guaurds, hooks and Maxx hand warmers are going to help though And I bought a proper Fly 5" riser.



And then of course I was having carb issues. Pulled the engine out 5 times yesterday and cleaned the carb 5 times. Fifth time was the charm. Idle circuit had something in it. We don't run an air filters and that circuit has a port on it that draws air. I'm sure we got a piece of chaff or canola stubble in it! Idles sweet again with 3000 rpm clutch engagement. Spins the track when you pin it. Replaced the coil as well with an OEM honda coil. We got RPMs! No power up that high but pulls good to 6500 RPM under load.

 
Mar 13, 2019
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So we have 100 miles on this set up and it's pretty good for the fields and on the trail. I'm running 2.5:1 gearing with 16 tooth front 40 tooth rear. It's pretty good in all but the deep heavy snow. (it was 0c here) and does 30mph. Snow is drifted so lots of bumps. The sled is so light it spends a lot of time in the air! hahaha I am going to make up another chain for a 3:1 gearing for the deeper snow. It should get us about 25mph. The back coil over isn't doing much as the angle is all wrong. I am going to find a shorter shock/coilover and angle it the other way.

IF I was starting over I would design the skid/suspension more like a big sled and not have just the single pivot point. Maybe the design of race shock kit from Rec supply would help. There is just to much movement in an arc for my liking with the stock polaris 120 set up.

But the kid loves it.

 

Reeb

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The Cat has lots of room. That’s an ordeal you got going on with the Polaris.

I used these on the KC. Maybe an option for you?
The wheels are mounted onto some alum I spun on the lathe. And the plastic slider is from like a 80’s Cat trail sled.




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Reeb

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The Rec Race Kit is good for us so far. Racers say the shocks blow out but ours are fine. And they come with spare heavier springs. I did mount mine differently than how they say to. I needed to get my ride height right and it makes it better for my 8yo. They come with idlers too. Makes it easy to clean that all up but for a price....I don’t have to tell you about that.

I might shorten the back of my rails and move the bracket forward, slide the skid back a few more inches than I did. The front springs have a wicked rebound so I’m not sure I’ll achieve what I want with the current setup.




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meathooker

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My advice, sell, sell, SELLL and buy a 200 bahahahah
love the thread. There is a ton of great info in here and your work is impressive!

we‘ve got 3 120’s. One bone stock cat, one Polaris with gov removed, and one with the Rec motor Honda, cut head, rear shock kit, 35 chain clutch kit, big bars etc.

Luckily found and picked up Yamaha 200 in December

i couldnt agree with your statement more!
 
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