840cc big bore update

chase · 03-01-2008, 07:57 AM

some of you may already know from some of the other sites about my teryx project. i've got a 840 kit w/stage III cams from Mickey at FST, vdi,. drilled nine 1" holes in the air box lid, and two days ago completed a full exhaust system for it. the exhaust i fabbed from mandrel bent tubing, started at the heads with vw exhaust flanges, they are a perfect fit. then made the first 12" out of 1.5" then stepped up to 1.625". overall length ended up being 40.5" that is as short as possible the front can be made, i even raised the front header over the flywheel cover to shave every inch i could. the rear i made equal length then combined them into a 1.75" to 2.25" merge collector that i also fabbed. the muffler is a hushpower II shorty with 2.25" in and out. once it was done i wrapped the headers with thermal wrap to help with the heat. i rejetted the carbs with mains that i drilled out to 3/32" and turned the screws out two full turns, one turn is stock. it was fast with just the 840 kit, but this exhaust really woke it up. the top end power is nuts, it now pulls hard all the way to the rev limiter, in fact, once the belt reaches the top of the primary and the rpms increase it starts pulling harder, so some clutch work is next to get everything out of it. i also own a long travel sand car with CBM built 402ci stroked ls2 and Fortin box, so these side by sides have never really impressed my with there power, until now, this thing puts a smile on my face.
i want to thank Mickey Dunlap at FST for all the help with this and the exhaust recommendations, he really knows these motors, thank you!
i would be happy to post some pics if some one can get me permission. for now thats it, i can't imagine needed a more powerfull side by side!

**PIPO** · 03-01-2008, 08:49 AM

If you own a sand car with a CBM built 402ci stroked ls2 and you say your side by side is fast I believe you. Enjoy it!

DonkeyKong · 03-01-2008, 08:49 AM

If you want send me the pics and I will post them for you.

blondebxer@yahoo.com

**sunrayV** · 03-01-2008, 10:40 AM

Post us some vid's. This sound like a "must see and hear".

chase · 03-01-2008, 11:40 AM

Quote:

If you want send me the pics and I will post them for you.

blondebxer@yahoo.com
[/b]

pictures sent!

Quote:

If you own a sand car with a CBM built 402ci stroked ls2 and you say your side by side is fast I believe you. Enjoy it!
[/b]

i'm not saying its anything like my sandcar, but the power my teryx has is impressive.

**PIPO** · 03-01-2008, 12:41 PM

I know what you meant bro. I had a 427rwhp LS1/LS2 SS.

xchamp · 03-01-2008, 01:01 PM

Good to hear Chase, now Im really debating on going with a standard bore with stage 2's or the 840 kit with the stage 3's. What kind of riding due you do, Im assuming dunes, since you have a sand rail. Im all PA mountains and woods and dont think I'll be able to use all the topend with the 840 and stage 3's

!

DonkeyKong · 03-01-2008, 01:02 PM

I am working on the pics.They should be up soon.

chase · 03-01-2008, 01:22 PM

Quote:

Good to hear Chase, now Im really debating on going with a standard bore with stage 2's or the 840 kit with the stage 3's. What kind of riding due you do, Im assuming dunes, since you have a sand rail. Im all PA mountains and woods and dont think I'll be able to use all the topend with the 840 and stage 3's

!
[/b]

with the side by side both dunes and trail riding. this 840 is way more than is needed for trails but you don't have to use all the power all the time. the new exhaust headers i built didn't seem to hurt the low end power at all, it just made it scream up top. i'm sure either way you go you'll be happy!

xchamp · 03-01-2008, 01:26 PM

Yeah I know Chase, if it was a quad it would be a no-brainer. But since this is getting a full roll cage and back seat, its going to be the family hauler in the woods, I leaning towards the standard bore kit. Ive had three of Mickeys motors and have been happy with everyone of them. Most happy with the last one, it made the most HP!

03-01-2008, 08:49 AM	#2
PIPO Premium Member Feedback Score: 3 reviews Join Date: Dec 2006 Location: Augusta, GA Posts: 5,294 (0)	If you own a sand car with a CBM built 402ci stroked ls2 and you say your side by side is fast I believe you. Enjoy it! __________________ KFX 800 AMR/ASR/Diamond/DG/Dynatek/Elka/Falicon/GT Thunder/JH Clutch/Muzzy Super Pro/WEB YFZ 450 CP/CCP/FCI/Fox Evol DSC/Fox Podium/Hiper/Houser/JD/Nmotion/REM/Team axle

03-01-2008, 08:49 AM	#3
DonkeyKong Senior Member Feedback Score: 0 reviews Join Date: Mar 2007 Location: Parkersburg,WV Posts: 5,006 (0)	If you want send me the pics and I will post them for you. blondebxer@yahoo.com __________________ WVSwampDonkey now know as DonkeyKong

03-01-2008, 10:40 AM	#4
sunrayV Premium Member Feedback Score: 1 reviews Join Date: May 2004 Location: Texas Panhandle Posts: 651 (0)	Post us some vid's. This sound like a "must see and hear". __________________ 04 orange V--FST 700 W/stage 3 cams--Muzzy exhaust jet hotted--K&N filter w/outerwear-- 15- 1" holes in lid--Elkas on front--GT Thunder rear shock conversion--orange flamed shock pros-- Dalton overdrive clutch cover--VFJ Stage III clutch W/spacer--pink, blue, maroon & o/bl springs--Venforcer's HD tie rods--3/32 Fr & 3/32 R--VFJ UPP intake--Trail Tech computer--Trail Tech X bars with Trail Tech bar clamp--Ims 4.6 fuel tank--DG fat series bumper, grab bar, & A-arm gaurds--Pro Armor nerfs--Engine ice w/ thermostat removed--custom graphics (XS Graphics)--6* key--power madds--'05 modded rocker shafts--YFZ catch can--Custom Dynamics tail light--Tiny Tach--Custom shorty shifter--Spider grips--Reverse Override bypassed--Polished slides-- Shortened carb springs--needles shimmed .020"--Pro Armor foot peg ext's--+4 swingarm extention--24" Extremes on rear-- sand Stars on front for sand-- holeshots all around for trail Wifes: '07 black V--12 hole mod--twin air filter--pink spring--WLD OTZ secret exhaust mod--six pack rack--Sand Star's fr. & rear for sand--Stock holeshots for trail. Ride the Texas Panhandle area

03-01-2008, 12:41 PM	#6
PIPO Premium Member Feedback Score: 3 reviews Join Date: Dec 2006 Location: Augusta, GA Posts: 5,294 (0)	I know what you meant bro. I had a 427rwhp LS1/LS2 SS. __________________ KFX 800 AMR/ASR/Diamond/DG/Dynatek/Elka/Falicon/GT Thunder/JH Clutch/Muzzy Super Pro/WEB YFZ 450 CP/CCP/FCI/Fox Evol DSC/Fox Podium/Hiper/Houser/JD/Nmotion/REM/Team axle

03-01-2008, 01:01 PM	#7
xchamp Senior Member Feedback Score: 0 reviews Join Date: Jun 2006 Posts: 1,930 (0)	Good to hear Chase, now Im really debating on going with a standard bore with stage 2's or the 840 kit with the stage 3's. What kind of riding due you do, Im assuming dunes, since you have a sand rail. Im all PA mountains and woods and dont think I'll be able to use all the topend with the 840 and stage 3's ! __________________ 2 TIME GNCC UTILITY UNLIMITED CHAMPION 2008 TERYX LE: FST 840, STAGE 3 CAMS, VDI, MUZZY EXHAUST, DALTON CLUTCH, VFJ ROLLER, ELKAS, THUNDERHAWK PERFORMANCE 2 SEAT RACE CAGE, DOOR BARS, BUMPERS AND BRACES, BEARD TSX SEATS, 5PT. CROW HARNESS, 14" CHROME DIABLOS, GBC GRIM REAPERS, PRO ARMOR SKIDS, TEAM GREEN PLASTIC 2008 TERYX: ORANGE MAIER PLASTIC, THUNDERHAWK PERFORMANCE 4 SEAT CAGE, BUMPERS, DOOR BARS AND BRACES, BEARD TSX SEATS, DOUGLAS SPIDERS, MAXXIS BIGHORN 2.0, VDI, THE FAMILY CRUISER!!

03-01-2008, 07:57 AM	#1
chase Member Feedback Score: 0 reviews Join Date: Feb 2008 Posts: 50 (0)	some of you may already know from some of the other sites about my teryx project. i've got a 840 kit w/stage III cams from Mickey at FST, vdi,. drilled nine 1" holes in the air box lid, and two days ago completed a full exhaust system for it. the exhaust i fabbed from mandrel bent tubing, started at the heads with vw exhaust flanges, they are a perfect fit. then made the first 12" out of 1.5" then stepped up to 1.625". overall length ended up being 40.5" that is as short as possible the front can be made, i even raised the front header over the flywheel cover to shave every inch i could. the rear i made equal length then combined them into a 1.75" to 2.25" merge collector that i also fabbed. the muffler is a hushpower II shorty with 2.25" in and out. once it was done i wrapped the headers with thermal wrap to help with the heat. i rejetted the carbs with mains that i drilled out to 3/32" and turned the screws out two full turns, one turn is stock. it was fast with just the 840 kit, but this exhaust really woke it up. the top end power is nuts, it now pulls hard all the way to the rev limiter, in fact, once the belt reaches the top of the primary and the rpms increase it starts pulling harder, so some clutch work is next to get everything out of it. i also own a long travel sand car with CBM built 402ci stroked ls2 and Fortin box, so these side by sides have never really impressed my with there power, until now, this thing puts a smile on my face. i want to thank Mickey Dunlap at FST for all the help with this and the exhaust recommendations, he really knows these motors, thank you! i would be happy to post some pics if some one can get me permission. for now thats it, i can't imagine needed a more powerfull side by side!

03-01-2008, 11:40 AM	#5
chase Member Feedback Score: 0 reviews Join Date: Feb 2008 Posts: 50 (0)	Quote: If you want send me the pics and I will post them for you. blondebxer@yahoo.com [/b] pictures sent! Quote: If you own a sand car with a CBM built 402ci stroked ls2 and you say your side by side is fast I believe you. Enjoy it! [/b] i'm not saying its anything like my sandcar, but the power my teryx has is impressive.

03-01-2008, 01:02 PM	#8
DonkeyKong Senior Member Feedback Score: 0 reviews Join Date: Mar 2007 Location: Parkersburg,WV Posts: 5,006 (0)	I am working on the pics.They should be up soon. __________________ WVSwampDonkey now know as DonkeyKong

03-01-2008, 01:22 PM	#9
chase Member Feedback Score: 0 reviews Join Date: Feb 2008 Posts: 50 (0)	Quote: Good to hear Chase, now Im really debating on going with a standard bore with stage 2's or the 840 kit with the stage 3's. What kind of riding due you do, Im assuming dunes, since you have a sand rail. Im all PA mountains and woods and dont think I'll be able to use all the topend with the 840 and stage 3's ! [/b] with the side by side both dunes and trail riding. this 840 is way more than is needed for trails but you don't have to use all the power all the time. the new exhaust headers i built didn't seem to hurt the low end power at all, it just made it scream up top. i'm sure either way you go you'll be happy!

03-01-2008, 01:26 PM	#10
xchamp Senior Member Feedback Score: 0 reviews Join Date: Jun 2006 Posts: 1,930 (0)	Yeah I know Chase, if it was a quad it would be a no-brainer. But since this is getting a full roll cage and back seat, its going to be the family hauler in the woods, I leaning towards the standard bore kit. Ive had three of Mickeys motors and have been happy with everyone of them. Most happy with the last one, it made the most HP! __________________ 2 TIME GNCC UTILITY UNLIMITED CHAMPION 2008 TERYX LE: FST 840, STAGE 3 CAMS, VDI, MUZZY EXHAUST, DALTON CLUTCH, VFJ ROLLER, ELKAS, THUNDERHAWK PERFORMANCE 2 SEAT RACE CAGE, DOOR BARS, BUMPERS AND BRACES, BEARD TSX SEATS, 5PT. CROW HARNESS, 14" CHROME DIABLOS, GBC GRIM REAPERS, PRO ARMOR SKIDS, TEAM GREEN PLASTIC 2008 TERYX: ORANGE MAIER PLASTIC, THUNDERHAWK PERFORMANCE 4 SEAT CAGE, BUMPERS, DOOR BARS AND BRACES, BEARD TSX SEATS, DOUGLAS SPIDERS, MAXXIS BIGHORN 2.0, VDI, THE FAMILY CRUISER!!

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