Everyone asks this question so here are some ideas to think about when putting a 6/800 into your 440 chassis.
1st off there are two ways you can go about this. You can use all the 440 electronics/mpem/stator/volt reg. and then just have the mpem reprogrammed to the correct curve by Tom Lawrence. OR you can do the better more expensive thing and use all the electronics off the 6/800 motor. That would include the 360 watt stator, larger volt. reg., full body wire harness, and mpem.
If you use the 440 mpem you will not have RER or DPM and you will have your lights dim when using your hot grips do to it's 290 watt stator.
Some may disagree on this with me, but this next step is important....BUY the full length tunnel cooler off a wrecked sled and replace the 440 small one. Don't take the chance of running a 440 cooler with that bigger motor. With that you will need the two coolant hoses that run from the cooler to the motor. You can use the 440 coolant bottle and hoses off it. First you need to remove the restrictor found inside the coolant hose that runs to the head. 2nd you need to drill the hole in the nipple for the hose that will run your heated carbs(assuming you have heated carbs which are stock).
The 6/800 motor will bolt right in the exact motor mount of your 440.
You will probably want to add the oil tank and hoses for the oil injection setup unless you like to mix gas.
Before you put the motor in, it's best to mount the new larger voltage reg. in it's place since it sits down low and is hard to get to.
Obviously you need the appropriate exhaust setup which will also just drop right in place.
You need the 6/800 fuel pump too since it has just one outlet where as the 440 has 2.
You can use the 440 clutches. Just buy a good set of adjustable pins and some new ramps. 414's or 415's work good with the 800 motor. Green/Blue spring is a good start point (200/290). About 19-20 grams is another good starting point.
2ndry: Stock Team. The stock spring is fine, but you'll need a new helix with a RER(reverse) cut in it (assuming you have the stock 6/800 mpem with RER.
58/44/46 all the way up to 70/44/46 are good to play around with on the 800's.
The stock 440 handlebar controls and hot grip switch will work with the 6/800 full body harness. You just need to buy or find a connector so that you can wire in everything off your bars to it and just plug it in. I have the pinout if you need it...send me a PM.
Don't forget to buy a manual so you know how to adjust your oil pump, appropriately torque all your bolts, and other things you might need.
Ebay has them for like $10 on CD and it includes the Race Manual which is important for the 440 chassis setup and shock rebuilding.
Anything I missed...PM me and I'll add it to this list.
Wire pinout for 440 controls to the main 6/800 body harness.
Item Wire Color Pin I.D.
________________________________
Brake---- white--- 3
Brake---- red/yellow --4
Left Hot Grip---- orange-- in from switch
Left Hot Grip---- orange/violet-- in from switch
Left Hot Grip---- black--- 1 or Grd.
Right Hot Grip---- orange-- in from switch
Right Hot Grip---- orange/violet-- in from switch
Right Hot Grip---- Grey/Yellow -- 1 or Grd.
Thumbwarmer---- brown-- in from switch
Thumbwarmer---- brown/yellow-- in from switch
Thumbwarmer---- yellow/black-- 1 or Grd.
Dimmer-- grey -- 10
Dimmer-- red/orange-- 11
Dimmer-- grey/violet --12
RER Switch---- beige-- 8
RER Switch---- red/grey-- 5
Kill Switch black--- 1
Kill Switch black/yellow--- 2 in 03/6 in 04
Hot Grip/Thumb Switch--- red/yellow --13
Hot Grip/Thumb Switch--- orange-- out to element
Hot Grip/Thumb Switch--- orange/violet-- out to element
1st off there are two ways you can go about this. You can use all the 440 electronics/mpem/stator/volt reg. and then just have the mpem reprogrammed to the correct curve by Tom Lawrence. OR you can do the better more expensive thing and use all the electronics off the 6/800 motor. That would include the 360 watt stator, larger volt. reg., full body wire harness, and mpem.
If you use the 440 mpem you will not have RER or DPM and you will have your lights dim when using your hot grips do to it's 290 watt stator.
Some may disagree on this with me, but this next step is important....BUY the full length tunnel cooler off a wrecked sled and replace the 440 small one. Don't take the chance of running a 440 cooler with that bigger motor. With that you will need the two coolant hoses that run from the cooler to the motor. You can use the 440 coolant bottle and hoses off it. First you need to remove the restrictor found inside the coolant hose that runs to the head. 2nd you need to drill the hole in the nipple for the hose that will run your heated carbs(assuming you have heated carbs which are stock).
The 6/800 motor will bolt right in the exact motor mount of your 440.
You will probably want to add the oil tank and hoses for the oil injection setup unless you like to mix gas.
Before you put the motor in, it's best to mount the new larger voltage reg. in it's place since it sits down low and is hard to get to.
Obviously you need the appropriate exhaust setup which will also just drop right in place.
You need the 6/800 fuel pump too since it has just one outlet where as the 440 has 2.
You can use the 440 clutches. Just buy a good set of adjustable pins and some new ramps. 414's or 415's work good with the 800 motor. Green/Blue spring is a good start point (200/290). About 19-20 grams is another good starting point.
2ndry: Stock Team. The stock spring is fine, but you'll need a new helix with a RER(reverse) cut in it (assuming you have the stock 6/800 mpem with RER.
58/44/46 all the way up to 70/44/46 are good to play around with on the 800's.
The stock 440 handlebar controls and hot grip switch will work with the 6/800 full body harness. You just need to buy or find a connector so that you can wire in everything off your bars to it and just plug it in. I have the pinout if you need it...send me a PM.
Don't forget to buy a manual so you know how to adjust your oil pump, appropriately torque all your bolts, and other things you might need.
Ebay has them for like $10 on CD and it includes the Race Manual which is important for the 440 chassis setup and shock rebuilding.
Anything I missed...PM me and I'll add it to this list.
Wire pinout for 440 controls to the main 6/800 body harness.
Item Wire Color Pin I.D.
________________________________
Brake---- white--- 3
Brake---- red/yellow --4
Left Hot Grip---- orange-- in from switch
Left Hot Grip---- orange/violet-- in from switch
Left Hot Grip---- black--- 1 or Grd.
Right Hot Grip---- orange-- in from switch
Right Hot Grip---- orange/violet-- in from switch
Right Hot Grip---- Grey/Yellow -- 1 or Grd.
Thumbwarmer---- brown-- in from switch
Thumbwarmer---- brown/yellow-- in from switch
Thumbwarmer---- yellow/black-- 1 or Grd.
Dimmer-- grey -- 10
Dimmer-- red/orange-- 11
Dimmer-- grey/violet --12
RER Switch---- beige-- 8
RER Switch---- red/grey-- 5
Kill Switch black--- 1
Kill Switch black/yellow--- 2 in 03/6 in 04
Hot Grip/Thumb Switch--- red/yellow --13
Hot Grip/Thumb Switch--- orange-- out to element
Hot Grip/Thumb Switch--- orange/violet-- out to element
