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well first you should look up what wiseco/oem make for oversize pistons for that sled. That will give you a few options on how much to bore the cylinders. You have to bore the cylinders to match the size of available pistons on the market, not just bore it out and hope you'll find a piston that will fit.

make sure you are 100% positive you know the difference between a 1996 XCR 600 and a 1996 XCR 600 SP.
 

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This graph will give you a good idea:

Fuji Motor

Indy XLT600 95-97
INDY XLT/SKS 600 1996
INDY XLT Special 97-99
INDY XLT Classic 98-99
INDY XLT Touring 96-99
INDY 600 XCR 95-97
INDY XLT/RMK 95-97
XC700 Triple 1997
Indy Triumph 2000

*Piston Port
*Pro Lite (Includes Wrist Pin)
*Cast Iron Bore 3 65x60 597 STD MDISK1167 $289.95
after 5% discount and checkout
& only $7.95 SHIPPING
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65.5x60 607 0.50 MDISK1168 $289.95
after 5% discount and checkout
& only $7.95 SHIPPING
Quantity:

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66x60 616 1.00 MDISK1169 $299.95
after 5% discount and checkout
& only $7.95 SHIPPING
Quantity:

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66.5 X 60 652 1.50 MDISK1278 $299.95

The above info came from the site listed below:

http://www.psep.biz/store/polaris_snowmobile_rebuild_kit.htm
 

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yeah it's not going to be cheap. no point to bore out cylinders unless you have a cylinder that is scored bad. boring cylinders to gain performance (which is what I assume you are wanting to do...) gives you the least bang for your buck.
 

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Polaris_Parts_MN said:
yeah it's not going to be cheap. no point to bore out cylinders unless you have a cylinder that is scored bad. boring cylinders to gain performance (which is what I assume you are wanting to do...) gives you the least bang for your buck.
I agree with Polaris_Parts_MN, if you looking for more performance by doing a big bore then for maximum gains you will also need porting and head mods that go along with it, not to mention a set of pipes that will compliment all of the above mentioned work, dollars start flying out pretty fast when wanting to do all of this that is for sure.
 
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