sledhead for life
Join Date: Nov 2009
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A big bore kit replaces your stock cylinders and pistons with larger cylinders and pistons to increase cc's. Usually, a different pipe/can is also required, and sometimes a reflash of your ECU will be necessary.
If you are considering a kit on your 800, SLP makes a nice one.
Polaris - Peformance Edition Package for 2002-05 Polaris 800 VES - Starting Line Products
You can also get a lot of bang for your bucks by going to an SLP singe pipe/can, SLP intake, and V-ForceIII reeds. Clutch to SLP specs and hold on! Just adding the pipe/can and intake stuff will bump you close to 150 hp up from 136, which is VERY noticable in the Edge. My 02 was set up like that and was a very fun sled to ride.
If you're going to keep your Edge for a while, I would consider buying a bottom end from Indy Specialty. Indy Dan does GREAT work and stands behind it. He really knows those 800 engines. Kind of spendy, but it will be the last time you have to worry about the bottom end on that engine!
The reflash would only be necessary if you are doing a big bore on an EFI engine. If you do the BB on your engine, you will have to rejet the carbs to add more fuel. It's REALLY critical to reflash the newer Polaris sleds, they are dangerously lean in the midrange as it is to comply with EPA standards.
The stroke is the same on the Edge BB, you use the same bottom end with bigger cylinders and pistons. Some places will want your bottom end so they can do some modifications for better air flow as well.
Good luck in your choice! It gets confusing and can be spendy enough that you may consider getting a newer sled instead of fixing the old one!