Building a 500 to a 650 - ArcticChat.com - Arctic Cat Forum

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post #1 of 8 Old 06-18-2017, 02:23 PM Thread Starter
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Building a 500 to a 650

I picked up a lower miles 07 400 this week and as much as I like the Suzuki motor, I already have a 400 Eiger and am wanting a little more power. The schematic shows the 400 and 500 for that year to use the same frame and I thought about swapping the 400 motor out with a 500. I have a 500 Suzuki motor that I could build so it wouldn't be that much trouble and with what I get for the 400 motor and electrical I would come out about even. My question is about the 500 motor. It seems like I remember reading you could bore the cases and it would receive the 650 cylinder and that the heads were the same. If I'm going to go ahead and go into the bottom end and rebuild the motor it wouldn't be much price difference. Is there anyone who has done this or has any information? I'm not 100% set on it yet because I hate tearing into a perfect running bike but definitely considering it. Thanks
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post #2 of 8 Old 06-18-2017, 06:39 PM
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ATV: 2008700SD and 2002 400 FIS
If you get your 400 running 100% , it will keep up with a 500, or darned close. I had a 500 with a Web Racing cam, 5 degree timing advance key, gutted exhaust, Dynojet stage 1 kit and had the carburetor tuned with a wideband. It was very torquey, and I was able to run 30" Mudzillas. It would top out over 60 mph on the gps. But, I'm pretty sure if you did the same mods to the 400, it would do nearly the same. I think you are right about up sizing the 500, but there is a lot you can do to the 400. Las week my business partner bought a Royal Enfield 500 Bullet, he said let's go for a ride, see if you can keep up. I ran my 400 wide open for 10 miles, it has 27" MST's. My buddy couldn't get by, said I was going 60, and his bike got wobbly above 60. My speedo read 53-55, btw. I only have a Dynojet stage 1 and gutted muffler. There are posts for around 2011 about putting the 650 top end on the 500, you'll have to search. My 500 dynoed at 29.5 rwhp which = 38-39 crank hp. The 650 H1's were only about the same.
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2008 AC 700 Diesel and 2002 AC 400FIS

Last edited by Wallamatogus; 06-18-2017 at 07:12 PM.
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post #3 of 8 Old 06-18-2017, 09:12 PM Thread Starter
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I have a salvage yard of about 200 bikes and over the years I've spent seat time on a bunch of different bikes. I usually ride whatever I have fixed and move on later. I really like both the 400 and 500 Suzuki motors that Arctic Cat used. I have a 400 Eiger right now my son rides and we hunt some off of. I think its one of the best hunting' normal riding bikes in the 400cc you can own. I think it has good power for what it is and it will no doubt keep up, but never thought it was that close to the 500 in the power category. I would guess my Eiger runs around the 50 mph range. I have had a 500 Vinson and an 05 500 Arctic Cat. The Vinson I remember showing up to about 62 on the speedo. I'm not convinced either way yet. I cleaned out the carb and got it running yesterday and seems like its going to run great. It has right under 1400 miles and still has the stock tires. The only problem with buying and selling bikes is wanting to keep too many
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post #4 of 8 Old 06-18-2017, 09:22 PM
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ATV: 07 500 auto 13 700 XT trv
2010 Mileage: 800
2007 Mileage: 800
2006 Mileage: 800
Yes it's been done. Cases have to bored for the 650 jug and IIRC the stroke is different so it will have to be decked or gasketed.

Dynojet/142m/45p/3rd/3turns--Clipped and drilled--Unifilter--Easy adjust PMS--L.C.V. mod--AC Swaybar--Exhaust mod--2"Snorkels--Sanny shock bushings-- Airdam stage 1--PSC phase 2--21/ 23gr rollers--Dalton yellow spring--.7mm shim--Sanny Steerlites--RTR Flex Bracket--2 up seat / pegs--Tach--AC handguards--28" Outlaw mst's--Skull tailight--Skull shifter--Self Resetting Breakers--1" Wheel spacers--Customcncparts Steering Damper--AC deluxe handwarmers--6000k HID'S hi/lo--AC Deluxe Bumpers--Inline Fuel Filter-- O2 sensor \AFR guage--Black Magic Full Stainless Exhaust System--Wireless Winch Remote--29.5 Outlaws--Fox Podium X Rear Shocks--
2013 700 XT trv eps stock



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post #5 of 8 Old 06-18-2017, 10:45 PM Thread Starter
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Originally Posted by doorfx View Post
Yes it's been done. Cases have to bored for the 650 jug and IIRC the stroke is different so it will have to be decked or gasketed.
I don't know if I want to go that far, too much can scare people when you go to get rid of it.. The company I use for my machine work does nickasil and if the piston can fit the wrist pin and there is room they can get it done. If there is enough room before the water jacket they may could just do a big bore on the 500 jug. Is there any chart that shows the wrist pin or top size of the rod to see if any other pistons might fit that setup?
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post #6 of 8 Old 06-19-2017, 07:44 AM
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ATV: 07 500 auto 13 700 XT trv
2010 Mileage: 800
2007 Mileage: 800
2006 Mileage: 800
Contact four stroke tech he does a bbk for the 500. Download the service manual for both from countrycat.com I'm pretty sure it lists bore and stroke.

Dynojet/142m/45p/3rd/3turns--Clipped and drilled--Unifilter--Easy adjust PMS--L.C.V. mod--AC Swaybar--Exhaust mod--2"Snorkels--Sanny shock bushings-- Airdam stage 1--PSC phase 2--21/ 23gr rollers--Dalton yellow spring--.7mm shim--Sanny Steerlites--RTR Flex Bracket--2 up seat / pegs--Tach--AC handguards--28" Outlaw mst's--Skull tailight--Skull shifter--Self Resetting Breakers--1" Wheel spacers--Customcncparts Steering Damper--AC deluxe handwarmers--6000k HID'S hi/lo--AC Deluxe Bumpers--Inline Fuel Filter-- O2 sensor \AFR guage--Black Magic Full Stainless Exhaust System--Wireless Winch Remote--29.5 Outlaws--Fox Podium X Rear Shocks--
2013 700 XT trv eps stock



It's mind over matter,If you don't mind,
It just doesn't matter

No Boost No Bottle
just balls and throttle
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post #7 of 8 Old 06-19-2017, 11:32 AM
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ATV: 2008700SD and 2002 400 FIS
What surprised me about the 500, and I'm sure, the 400, these puppies will rev! I put a tachometer on my 500, it would easily turn 8,500 in 4th gear. Never looked at the tach in 5th gear, but 64 on the gps. I think a race cam in the 400, 5 degree key, gutted muffler, dynojet jet needle and a fatter man jet, wouldn't surprise me if it would also do 64. Probably outrun a 650. What the 400 actually lacks is torque. After buying the AC Diesel, now I see what torque is all about. The 500 towed a big trailer much better, but the 400 is at least as fun to ride.

2008 AC 700 Diesel and 2002 AC 400FIS

Last edited by Wallamatogus; 06-19-2017 at 11:38 AM.
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post #8 of 8 Old 06-20-2017, 08:40 AM
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I think your bang for buck upgrade would be a BBK for the 500, it's a 581cc?????

Would be a cool build and a great machine when done.

05 650V2 LE, 09 550H1,04 Arctic Cat 50

"Your best teacher is your last mistake"
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