Redneck Racing Inc.  3510 S. Highway 89  Jackson,Wy 83001
Primary Phone: 307-734-7674  Secondary Phone: 307-413-5250

Gizmo                                                                                                                                       

Polaris Enhancement Kit
Currently Testing on other makes and models. 

Fully Patent Pending for REDNECK RACING, Inc.

WHY THIS KIT WAS MADE
Plain and simple.
Every rider out there wants to get the most life and horsepower out of their machine. For over three years we at Redneck Racing have been developing and testing our product and have succeeded in producing a product that does just that.

THE PROBLEM
In field tests machines exhibited cold coolant temperatures averaging around 120 degrees. After letting the sled sit with the engine off for five to ten minutes testing showed the temperature would spike to between 180 and 190 degrees. Upon restart engine temperature would drop to between 70 and 80 degrees within five seconds. At this point the rider would have to go through the warm-up again to get the machine back to normal operating temperature. If this was not done, scuffing would start to appear on the pistons.

THE START OF A SOLUTION
In early 2009, developers installed a bypass in the main coolant line. As a result we extended the life of the engine by 200 miles, but it still was not good enough. Further testing led developers to install a bypass from the head to the water pump cover along with an inline thermostat. Following installation machine temperature spikes were within normal operating conditions of around 160 degrees and never below 120 degrees. This maintains optimum heat soak of the system.

INLINE THERMOSTAT AND COOLANT BYPASS
Mounting the custom designed thermostat and housing in the return hose from the tunnel coolers was found to stop the cold coolant from hitting the engine. Installing the hot water bypass allows the water to continue to circulate until it reaches acceptable temperatures. The inline thermostat then opens, allowing preheated coolant to enter the water pump housing and begin to circulate through the engine and the coolers. In deep snow conditions and extreme cold, when the coolant is rapidly cooled below the optimal operating condition, the inline thermostat will close and the bypass will preheat the coolant to the proper temperature before it is allowed back into the engine.  This stops the cooling system from cold shocking the engine.

GIZMO
Inline Thermostat
Field Test on 2009 Polaris 800 Assault
In field tests 2000 miles were put on the 800 in a two week period with varying weather, snow conditions, riding areas and elevations. The 800 was put through its paces with the intent of producing a motor failure. The variable exhaust valves were removed every night, so the pistons could be inspected and the findings were documented. In 2000 miles there was never so much as a scratch on the pistons.

TRUE HORSEPOWER
We determined that a sled running at its optimal working temperature will constantly produce it’s true horsepower. When the coolant temperature would not remain consistant, the ecu would have to compensate by detuning the engine

TEMPERATURE
Field tests revealed we were able to maintain a constant engine temperature of between 145 and 160 degrees. Allowing the motor to perform at its true horsepower all day long, regardless of the conditions.

TRIAL AND ERROR
As with any new design there are always bugs to be worked out. With the first inline design, testing found that the low temperature plastic fittings that were used would not stand up to the engine and exhaust heat. We also discovered that a housing made of any form of metal retained too much heat soak, and did not allow the thermostat to work properly.
This is why we test.

FINAL DESIGN
As developers continued to improve on the design, they settled on the high temperature injection molded two piece unit with the bypass built in to the housing itself.  This made a compact yet light weight kit that met all testing requirements but was fairly easy to install.

TRUE TESTING
How much difference does this kit make? Developers took one test unit and decided to do further testing by removing the inline thermostat, just to see how much difference the kit was making.

MACHINE FAILURE
After 2000 miles with the hot coolant bypass and the inline thermostat developers felt that they truly needed to know. Developers removed the inline thermostat and made it only 49 miles before they lost the PTO side piston. Developers felt that had the kit not been removed, the test sled would have continued to run well beyond expectations.

OTHER APPLICATIONS
With further testing, we feel that not only will this eliminate the Polaris 800 runnablity problem, but would control the temperature in the 600 and the 700 class machines by bringing the coolant temperature up and staying consistant the sleds will produce their true horsepower.

Thank You,
The Redneck Racing Team