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453 Posts
Discussion Starter · #1 ·
For the last couple of years, I've been riding my 2003 XC SP 600 121". This has been an excellent sled to me, with the 660 kit in it, she really rips! My riding buddies all started getting bigger and bigger displacement snowmobiles. While my 660 dealt its own hand, it was nothing compared to the ride, handling, and power of more modern rider-forward, big cc machines. It was time to upgrade. I've been looking for a new/new-used sled for some time now, everything from Yamaha Nitro's to Ski-doo E-tec(600)'s to all kinds of Dragons. Everything was either crappy, deals fell through, or I just couldn't choke up the money for what the sled was. Until this thing. I thought the same thing everyone else did when you hear "Polaris 900". I've heard of the things being a Polaris problem child. I decided to look a bit more into these 900's. With days after days of research, I decided to go take a look at this sled at the dealership. In February, negotiations began, then ended, the began again. Finally, on April 12th, the salesman and I came to an agreement that we could both be happy with. $6000.00 included the "115" belt, cover, 171 Woody's studs installed, a hat, registration, taxes and delivery.

I knew that after buying the sled, that wasn't going to be it. These sleds were indeed problem child's, but being the sled was already four and a half years old, guys had these things figured out for good. All summer long, I began investing in parts and ideas.






I began with the SLP Engine stabilization. This includes two parts, a torque arm and a push arm. They are said to increase vibrations in the chassis a little bit, but should be well worth it, due to the fact these 900's were ripping engine mounts apart often. With my sled being a MY06, it already had big improvements over the MY05, like the two added injectors, the pistons and cylinders were different, as well as improved engine mounts.

I'm pretty sure it would be almost impossible to put the torque arm in without removing the primary clutch. This kit can't be installed with electric start because it uses the bosses in the engine block where the starter would go. I removed the suitcase of an exhaust can to install the SLP push arm as well.




While the primary clutch and the exhaust canister were off, it was time to install the SLP hot air elimination kits on both sides. These are pieces of laser cut aluminum with a fine mesh over the openings to allow air to flow through, but not water or snow. It's a really funny feeling cutting that big of a hole into a brand new snowmobile!





This should allow for some air to come in!



This is what I used to cut into the plastic. Had I known then what I know now, I wouldn't have dremeled the entire opening out, I would have just drilled nine holes instead...but oh well.


The clutches were said to be horribly out of balance from the factory, and this was contributed to a lot of the chassis vibration. I then sent in my primary and secondary clutch with the new 321115 belt to get balanced. Before the 115 belt can be installed, the primary clutch needs to be adjusted to .10" - .20" of side clearance. I'm a nut for always trying to support the local businesses, so the clutches got sent to Motorsports Factory in Waukesha, WI for the balancing. They sub'd it out to some guy in northwestern Wisconsin. Had I known that, I would've just shipped it out to Dan at Indy Specialties in Welch, MN. It seems as though he did a pretty good's hard to tell without the sled running yet! There are lots of additional holes in both of the clutches.






The airbox on these snowmobiles are extremely heavy. They also block a ton of fresh air from the hood to the clutches. A call to Paul at Fire n Ice Performance should cure my problem. I had some troubles installing the bracket for the rear of the intake, everything functions and lines up pretty good. I think I'll just deal with the way it looks for now and fab something up next spring. I also need to move some wiring around to make the pin fit for the new belt guard.







Everyone who owns one of these sleds says you can't have enough venting for it. The temperatures rise ridiculously hot under the hood and are known to cause melted wires, melted panels and even melted recoil ropes! I didn't want to cut big holes in my new hood, so I opted for something a little more sophisticated. I stumbled across these vents from Mountain Fit Hoods.






Drilling big holes vs. cutting out the entire shape that you need will keep a little bit of material to hold its structure. Although it doesn't flow as much air, it's worth the sacrifice of having it be a little stronger.

Last but not least, I wanted to add some bling to my sled. This was achieved with a LED tail light from Bluhm Enterprizes. After taking delivery of it, I then noticed that it wouldn't work with the MY05-06 SwitchBacks. It was meant for the MY07 and later sleds with CFI. Rather than returning it, I plugged it in to see if it would even luck. Having a good understanding of electronics and nothing better to do, I started probing around wires to see what I could do. Just had to re-solder some wires to make it work. Now just to make it fit into the housing. After some .080" plexiglass, and about an hour of time, I glued these pieces to the ends of the original unit, viola! BLING BLING HOMIES!













I'm not sure how many of you guys know this, but on October 27th, I lost the tips of two of my fingers in a work accident. The surgeons had to reconstruct a lot of the tissue on two of my fingers, skin graft some more tissue, as well as rebuild the flexor tendon on my left hand. I've been sitting at home since, and did most of this work with only one hand! I'm physically not able to ride yet, but hopefully in the next couple of weeks. Thanks for looking, and hopefully there is more to come!


3,029 Posts
Right on, looks like you are doing all the updates to ensure better longevity of the sled. Personally I think if someone likes to tinker like yourself you can't go wrong buying a late model 900 if you do all the update work yourself, these sleds can be had for cheap because of their lackluster rep.

453 Posts
Discussion Starter · #4 ·
Ugly_old_Poo_kid said:
Hopefully all that work doesn't void the warranty..
I've talked to the salesman that I bought the sled from and he had told me that Polaris was installing the Push/Torque arm on factory units that had problems as well as the vents, still under warranty. The dealership that I bought it at said they will still honor the warranty with the new air intake, but can't say for sure about other dealerships. Even if there is a problem, the Fire n Ice air intake is for the most part reversible. So if need be, for any type of engine failure, I would just re-install the OEM air plenum so there isn't any type of problem. When you really think about it though, the new air intake shouldn't alter anything, the MAF is going to read and send in fuel accordingly...

276 Posts
Should be a pretty sweet ride, the 900's can be pretty awesome sleds especially with the time and money you've put into it. Probably going to be tinkering and tweaking for another year with it but after that hopefully you'll be golden! Looks good! [thumb]
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