Polaris Sportsman 850 36V ESC & Lighting

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toycrusher
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Polaris Sportsman 850 36V ESC & Lighting

Post by toycrusher »

This is just a mud machine so there was really no use doing any paint work.
2015-01-02 06.53.30.jpg
I swapped to 350W motors, easiest swap in the world. The ESC swap turned out to be quite simple too! I ran the motor output to the stock shift switch, it was already rated for 24v so 36 shouldn't be a big deal. By doing that I was also able to reuse the original gas pedal and braking. The pedal must be pressed for power to reach the motors. When the pedal is released the original brake circuit is still there for braking. Sure he can open the throttle wide open and then press the gas pedal, shock loading the gearboxes, but that's not much different from when they use two feet and hit the brake pedal on and off in a normal ESC setup. :o

For the throttle I used an e-bike twist grip throttle with built in key switch and charge indicator.
2014-12-31 19.50.38.jpg
I didn't realize the charge indicator stays on all the time. Doesn't make much sense :? so now I may have to install a main power relay :x .
2015-01-01 21.41.50.jpg
The grips were a bit of a pain to install. They are meant for 7/8" handle bars and the Polaris only came with 3/4". On the left grip, I just tightened the set screw down good so it bit into the plastic and held. For the twist grip I spent waaaay too much time with a razor blade shaving down the original rubber grip to provide just enough clearance to be able to tighten the built-in clamp. I also had to shave the red hand guard to fit the key and LED indicator of the twist throttle.
rubber shavings from the handgrip
rubber shavings from the handgrip
I ran the throttle, key, and headlight wires through the steering column and into the belly where I mounted the ESC, Voltage step-down module, and accessory power distribution block. I hacked up a bit of the interior plastic to fit the 3 x 12v 12ah batteries, but it actually fit well. I added my tail light and now I just need the front fog lights. I got new lenses for the 850 front end, but I prefer the 700 series square fogs and front winch. I will swap to the 700 front end if I could just find those lenses!
2014-12-31 21.27.21.jpg
2014-12-31 21.27.50.jpg
2015-01-01 22.19.19.jpg
2015-01-01 21.42.10.jpg
2015-01-01 22.20.33.jpg
Again, it's ugly, but it's usually covered in mud so no one can tell :lol:


"I'm not nuts, I prefer to be called an enthusiast! "

"I've stood on the shoulders of geniuses, and taken the next step..." ;-)

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Master Project List
(F150 6x6, 36v Superpower, 24v Beach Ranger 4x4, McQueen "El Relampago", 36v Polaris, Mudvette, Lil jeep dragster & mudder, 36v Rzr, Lifted Cowboy's jeep, FJ cruiser, Lil quad 18v, etc...)

Toycrushers Master Wiring Diagrams
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toycrusher
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Re: Polaris Sportsman 850 36V ESC & Lighting

Post by toycrusher »

Told you it was always covered in mud and the paint wouldn't matter :lol: :lol: :lol:
2015-01-03 16.26.53.jpg
2015-01-03 16.27.16.jpg
Finished up my wiring. Sloppy even by my standards :roll: but it's tough working inside that dumb thing, even after hacking out lots of plastic :x ;)
2015-01-03 00.01.08.jpg
The lighted toggle switch I put in turned out to be quite blinding. I may have to darken it somehow, probably put a rubber boot on it at the very least.
2015-01-03 00.19.31.jpg
I also came up with a camber fix for these quads I'll share in a separate thread. viewtopic.php?f=60&t=17658 It came out working great, they've already burned through a few battery charges :o It does great muddy donuts now and he can control the power slides around corners with the variable throttle :D If there is one bug, it's that the shifter has to be held down for reverse but it's on the same side as the twist throttle. To back up he has to hold the lever then reach across with his left hand to twist the throttle. Confusing just to look at but he manages :D :lol:
2015-01-03 16.27.05b.jpg
trick to the camber fix
trick to the camber fix
Last edited by toycrusher on Mon Jan 05, 2015 8:41 am, edited 1 time in total.
"I'm not nuts, I prefer to be called an enthusiast! "

"I've stood on the shoulders of geniuses, and taken the next step..." ;-)

Image

Master Project List
(F150 6x6, 36v Superpower, 24v Beach Ranger 4x4, McQueen "El Relampago", 36v Polaris, Mudvette, Lil jeep dragster & mudder, 36v Rzr, Lifted Cowboy's jeep, FJ cruiser, Lil quad 18v, etc...)

Toycrushers Master Wiring Diagrams
Zeppe807
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Posts: 1
Joined: Tue Jul 21, 2015 2:33 pm

Re: Polaris Sportsman 850 36V ESC & Lighting

Post by Zeppe807 »

I have the 800 sportsman twin also, and I would like to use your solenoid wiring diagram to bypass the controller, and run 36v instead of the designed 24v. I have the smaller motors, but have the new upgraded controller and motors ordered from perego. I would like to play with the idea of the solenoid and the 36v. Is this an acceptable plan?

Thanks,
Joe Zeppe
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toycrusher
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Re: Polaris Sportsman 850 36V ESC & Lighting

Post by toycrusher »

This would probably be the easiest way to get it done

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"I'm not nuts, I prefer to be called an enthusiast! "

"I've stood on the shoulders of geniuses, and taken the next step..." ;-)

Image

Master Project List
(F150 6x6, 36v Superpower, 24v Beach Ranger 4x4, McQueen "El Relampago", 36v Polaris, Mudvette, Lil jeep dragster & mudder, 36v Rzr, Lifted Cowboy's jeep, FJ cruiser, Lil quad 18v, etc...)

Toycrushers Master Wiring Diagrams
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