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Well, I have been researching this for the past week and am not getting any definite answers, just speculation so any help is welcome. I got my hands on a 2009 Renegade 500 with a blown engine and if it's not too much trouble I'd like to fit an 800 engine instead. What parts do I need to make this work? Before you tell me it's more trouble than it's worth let's come up with a list and let me decide. I would get a used complete engine rather than rebuilding what I have. Computer and matching key. Can I use the stock wiring harness and just swap in the ecu & key? Cooling system the same? Clutching definitely different so is there a complete 800 clutch kit I could get or is it going to be a primary and secondary replacement? Exhaust? Anything else I'm forgetting? Can I use an 800 from an outlander or renegade of any year?
I'll admit the new Griffin 640 kit is intriguing but I'd rather get into a 800 based engine so I can BBK off of that. There are no used 800 or 1000 Renegades for sale in my state that I can find and I have been looking...
 

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What about difs? Are they going to be able to take the additional power of the 800? Or the axles? Is your 500 FI? If not will need to modify fuel tank or new one for fuel pump?
 

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I have been thinking of the same thing for a while now but I love my lil 500. If you get a fuel monster set up for a 800 it will save you having to change the computer. Mr rpm crank and 800 kit should probably solve your for engine swap (rebuild your 500 to a 800) or better still send him your old motor to rebuild. Dalton clutch kit is cheap and easy (500 has 4 light weights, 800 has 6 heavier weights). Clutch kit will have a primary and secondary spring as well as weights. Get a new slip on exhaust or full system (may as well if you your going this far with it). Hope I have been some help to you on this. Steve at monster industries, Greg at MrRpm shoot them some emails to get expert advice. Cheers



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Yes, get the crank/rod setup for $600. and a topend kit for $400. and you have an 800 for $1000. You'll need to tune it, or reflash the ecu to 800 specs, which is $400
 

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Yes, get the crank/rod setup for $600. and a topend kit for $400. and you have an 800 for $1000. You'll need to tune it, or reflash the ecu to 800 specs, which is $400

Or do this


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Or an 840+ top end...
Thanks for the replies, that was a big help!

Now ya talking, go hard mate. Never dream to big when living the dream, BBK Can-Am Cheers


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Most stuff shouldcswap over. The clutching is the same other than weights and springs. U could even pick that up used pretty easy. If i had it apart i would definitely 840 that beast you're adding cams and a reflash with fuel tuning so take it to the next level
 

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Yes, get the crank/rod setup for $600. and a topend kit for $400. and you have an 800 for $1000. You'll need to tune it, or reflash the ecu to 800 specs, which is $400
I'm in the process of doing the same, but already have the 800 engine to replace the 500. Can't get a straight answer if I NEED an 800 ecm, or have my 500 one refreshed. Or will the 500 one work with a pc5 to tune it?
 

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Yes, get the crank/rod setup for $600. and a topend kit for $400. and you have an 800 for $1000. You'll need to tune it, or reflash the ecu to 800 specs, which is $400
I'm in the process of doing the same, but already have the 800 engine to replace the 500. Can't get a straight answer if I NEED an 800 ecm, or have my 500 one refreshed. Or will the 500 one work with a pc5 to tune it?
Either way works, if you was here, I may have an ecu to swap with you, as it will need to be married to the dash & key, after install, can't simply swap em out. The 500 ecu works fine, after tuning with a PCV. I would install the 800, then put in the newer injectors, which are larger, and it'll be closer then with the 500 inj.
 

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Just one more potentially silly question, with the 500 ecm, will the timing be correct? With the 800 having a different stroke and whatnot? I've got the injectors with the 800 when I bought it, so I may give it a shot as is. Wait make that 2 silly questions,,,bike is 09 500 renegade, engine is from 06 outlander,,,What PCV would a guy get. They don't list one for 09 500. I could never understand how they have so many different part numbers when a do beck style will fit almost every machine

And if need be, I can send you my ecm, heck I can send you 2 500 ecm's for an 800 ecm. I have b.u.d.s software so matching to my bike is no problem.
 

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Just one more potentially silly question, with the 500 ecm, will the timing be correct? With the 800 having a different stroke and whatnot? I've got the injectors with the 800 when I bought it, so I may give it a shot as is. Wait make that 2 silly questions,,,bike is 09 500 renegade, engine is from 06 outlander,,,What PCV would a guy get. They don't list one for 09 500. I could never understand how they have so many different part numbers when a do beck style will fit almost every machine

And if need be, I can send you my ecm, heck I can send you 2 500 ecm's for an 800 ecm. I have b.u.d.s software so matching to my bike is no problem.
Timing won't be the same, but it's not enuf to matter. If you get my reflash, you can run a Maverick Powercommander, and adjust timing to your liking.

I have ecu's here, but when guys send em in, I don't know what they're off of. If I have a customer come in, and I know what it is, then I know, right now, I have two cores here, and don't know what they're off of. If you get a powercommander for the atv, get one for the '09 800.
 

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Ok thanks! Yeah I've got the ecm from the renegade and 1 from a wrecked 500 Outlander. "Borrowed" it to see if it would fix my stalling issue, which it didn't. Hence the motor swap
 

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Hey guys I have a question for you I’m new to this and just bought a 2007 renegade 800 high output and the engine is ticking I found a engine from a 2013 outlander 800 I was wondering if both the engines are compatible i know the part number are different but I was going to see if there’s anyway I can make it work and what I would need to make it work thanks for your time guys
 
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