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Polaris IQ440/600R trail conversions
We convert Polaris IQ 440 & 600R 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.

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Polaris IQR AxysR trail conversions
 NECESSARY ITEMS
Polaris large IQR/AxysR fuel tank with pickup, hose and fitting  $409
Tank Only
Polaris large capacity fuel tank 8.8 gallons-Fits 2005-2018 IQR/600R & 600RR. Will fit the '19+ 600R with heating/modification to match the bend in the tunnel. 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 2 of the pan head mounting screws sold below. All of our tanks work with our extra heat exchanger/cooler.
+ Shipping
(shipping is initially charged $75 in the USA-covers most areas. Canada is usually around $145 USPS Priority mail. All tanks will require a signature for delivery)
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Polaris Large IQR/AxysR fuel tank kit $479
Fuel tank with pickup, hose, fitting, bra, padding and instructions.
Polaris large capacity fuel tank 8.8 gallons-Fits 2005-2018 IQR/600R & 600RR. Will fit the '19+ 600R with heating/modification to match the bend in the tunnel. 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 2 of the pan head mounting screws sold below. All of our tanks work with our extra heat exchanger/cooler.
 + Shipping
(shipping is initially charged $75 in the USA-covers most areas. Canada is usually around $145 USPS Priority mail)
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Polaris IQR fuel tank bra $119
 Bra only. It can be vinyl dyed to any color.
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Polaris fuel tank mounting pan head screws  $3.60 a pair (recommended by us)
We recommend 2 for the tank mounting. 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.


10.5 Gallon Clear '05-18
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12.5 Gallon Clear '05-18


12.5 Gallon black '19-20


12.5 Gallon black '19-20
Trail Tank 10.5 and 12.5 Gallon Fuel Tanks
You will need to reuse your factory gas cap on this new tank.
"Tank only" will be just the tank.
"Tank kits" will contain all the internal parts - hose, clamps, filter, grommet and fitting.
Fuel gauge is standard/included and installed on black tank only.
Tanks were made to fit over the top of our heat exchanger.
Comes with all necessary mounting hardware, tail light relocation kit
and Installation Instructions  
12.5 gallon tanks will NOT work on 600RR (crossover hoses are in the way)
10.5's will work with 600RR.
'19-'20 AxysR/600R tanks will come prebent to match the tunnel.
(Shipping is initially charged $85 in the USA-covers most areas. Canada is usually around $145 and we will invoice you for the remainder. All tanks will require a signature for delivery)
Make sure to choose the correct tank for your year/model
Size





2021-PRESENT POLARIS 600R EFI TRAIL TANK $470-490K
11.8 G / 45 L (STOCK VOLUME: 3.4 G / 13 L)
COMES WITH MOUNTING HARDWARE
USES your OEM CAP
CAN BE FITTED WITH QUICK FILL RECIEVER
BLACK TANK COMES WITH GAUGE
WE RECOMMEND POLARIS OEM FUEL PUMP BELOW. This is an improved version over the stock one. Sold as pictured, nothing extra.
(Shipping is initially charged $85 in the USA-covers most areas. Canada is usually around $145 and we will invoice you for the remainder. All tanks will require a signature for delivery)
Natural/Creme is pictured.

Size

     
 

NEW EFI Fuel Pump $739.99
Special order, no cancellations or returns.

Select
IQR fuel tank lightIQ racer fuel tank lightIQR gas tank light

2 pictures courtesy of Mr Boon

NEW Fuel tank light $24.95
Light your tank up so you can see your fuel level and be more visible at night. Light available in Red or Amber.  Light is 1" in diameter 1/2" thick and contains 16 wide angle super bright LEDs. Three wire system has dual intensity. Wires can be attached at voltage regulator plug. Sealed circuit board. No mount included. Picture of sled tank using a red light at full intensity.

Color
Trail Tank pick up hose for Trail Tank tank  $40
For use with all Trail Tanks.
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In tank pick up filter #5 for Trail Tank tank  $40
For use with fuel tank hose.
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In tank hose clamp #6 for Trail Tank tank  $20pr
For use with fuel tank hose.
Fuel tank fitting and grommet #7 and #9 for Trail Tank tank  $39
For use with the Trail Tank fuel tank.
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Trail Tank Fuel Gauge  $45
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.
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Trail Tank Tail light relocation bracket $48
For use with the Trail Tank fuel tanks.
Trail Tank rear tank vent cap $8
For use with the Trail Tank brand fuel tanks.
Polaris 440 IQ 92 octane trail head kit $248
Fits 05-07 Polaris IQ 440 race sleds and '02-'04 Pro X and XR. This low compression trail head kit includes the 7 O-rings and 1 gasket needed to do the job. Comes with 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)
Special Order Only.
 
Polaris '08 600R stock head $240
 Will run on 92 octane. Special Order Only.
 
Polaris '09-'12 600R stock head $280
Will run on 92 octane. Special Order Only.


Aftermarket rear heat exchanger $185
Exchanger only. You will need hoses, clamps and rivets or bolts, sold separately below or purchase the kit below. Fits IQ 440-600 racers 2005 - 2018.  Mounts on the rear of the tunnel. Without this your engine will be sluggish after high RPMs. All trail converted IQR's should run an extra cooler. Its stock on the 600RR so you know how Polaris feels about it.  All of our fuel tanks work with our extra heat exchanger/cooler.

 

Aftermarket rear heat exchanger KIT $295
 Fits IQ 440-600 racers 2005 - 2018.  Mounts on the rear of the tunnel. Has a divider in the center to force coolant flow. Without this your engine will be sluggish after high RPMs. All trail converted IQR's should run an extra cooler. Its stock on the 600RR so you know how Polaris feels about it.  All of our fuel tanks work with our extra heat exchanger/cooler. U hoses will need trimmed to desired length. If trimmed short enough the black plastic cover will fit over the top. Sold as pictured. If you need extra clamps they are available below.

 
U Tube for aftermarket rear heat exchanger above $40ea
Order 2 when installing the aftermarket exchanger above or to replace both of yours. Will need cut to length. Just the u hose. Will not work with Polaris exchanger above.

polaris iq racer iqr rear cooler u tube hose 
Polaris supplement rear heat exchanger U Tube for 440/600 Racers $25ea
Just the U tube. Not for the 600RR. Order 2 to replace both of yours. You can trim 1" off the long side for a lower profile mount with stock cover. Special Order Only. Will not work with aftermarket heat exchanger above.

Polaris and Aftermarket rear heat exchanger hose clamp $9.50ea
Just the clamp.

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12 Rivets $12
 3/16" universal rivet, for use with rear heat exchangers above.
May come in black or silver. 

polaris iq racer iqr rear cooler u tube hose 
Polaris supplement rear heat exchanger U Tube for 600RR $17ea NLA
 Just the U tube. Not for the IQ 440/600R. Order 2 to replace both of yours. Special Order Only. Will not work with aftermarket heat exchanger above.
Timing control box $245
Timing control box. Advances or retards the timing up to 4 degrees. Required for 440/600 trail conversions or you will have pre-ignition. Run it on position G. Special Order Only.  
EXTRA ITEMS
Maxima Quick 2 Mix oil bottle $7
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 $9.9pr
 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.
 
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NGK Spark Plugs for 440-600 Race sleds $8pr
  


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Click to enlarge

 IQR/AxysR/600R 5.62" Outer wheel kit with your choice of wheel color/weight $87 each, 1 wheel with hardware
(red is $10 additional) Comes with hardware.
We recommend adding four extra outer bogie wheel kits for trail riding. This kit has one 5.62" wheel with a 6205 or 6004 bearing for use with stock IQR Hyfax. 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 other hardware (Includes 1ea of # 32 & 33) $77
(red is $10 additional)

Color

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Mounting Pictures
'11-'14 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.
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NEW Real Cool 5.63" wheels $104.95pr (1 left, 1 right)
New technology, like a fan, when mounted correctly they pull snow into the suspension for better lubrication and cooling. Could also be used to pull snow out. Wheels come with 6004 bearings.

Color
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NEW Real Cool 5.63" outer wheel kit $154.95pr (1 left, 1 right)
This kit will comes with 2 wheels, 2 mounts and all the regular hardware.
New technology, like a fan, when mounted correctly they pull snow into the suspension for better lubrication and cooling. Could also be used to pull snow out. Wheels come with 6004 bearings.

Color
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5.62" inner wheels with spacers $82.00pr 
 We recommend one pair of these to protect your 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. The spacers are already pressed in the bearings. May not work on the 2011 and newer without changing the shock reservoir and hose connectors.
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5.62" single inner wheel with spacer for '11 and up $44.00ea
 We recommend one of these to protect your hyfax and front track shock. We recommend adding this wheel first. This inner wheels has a hole drilled into it so that you can easily remove your front track shock bolt. The spacer is already pressed in the bearing.  
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Stock and Aftermarket Colored Hifax,
'05-'18 Black or White (OEM) $80pr Colors $96pr, '19+ Stock Black $100pr
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
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Stock (OEM) Long White Hifax,  74"  $90pr
(needs cut to length, will fit most long tracks) Same profile as stock Hifax. For use with stock 5.62" wheels
Color
Cargo Net $9.95
15" Square
hooks right on to IQ stock tunnel and rear bumper and will hold an average size back pack and shovel
Color
Polaris Premium AXYS PRORMK Polyester 3/4 Cover
Covers
 
polaris-handguards-red-2876845_small  Handguards
Block the wind and any snow roost just in case you get temporarily passed.
Polaris handguards are available here
Powermadd handguards are available here
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 $80
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. Not actual picture, the new style are 1.5" longer.

 
polaris iqr new large toe hooks
NEW Improved Toe Hooks $55.99pr NLA
Toe Hooks. Wider and stronger than the original.  Fits 05-current Polaris IQ race sleds + 600RR.  Installs in minutes.
 
Skinz sticky gripper seat wrap $249.95
 Fits Polaris IQ race sleds + 600RR.(special order) 
Many compatible colored accessories can be purchased here.

   Skinz rear bumpers
Many more parts available including all stock/OEM Polaris parts and accessories. Please Contact us
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