Major maintenance on the '05 900.

[otterpoo]

This sled has 2 previous owners who only used this for long trail riding in Northern Maine and Eastern Canada. I have put roughly 1,700 miles in 2 seasons, and needed to only replace suspension parts along with some minor mods and maintenance. It is stock minus Indy Dan worked primary/secondary, updated rear suspension, gutted air box, mod VES valves, black duct tape, Gripper skis, riser, and Skinz prefilters.
I need some opinions on the better route to go, and better places to buy some parts for the 900 to get it ready for the season. Here is a list of most things I am concerned with.

-fuel system maintenance- filters and maybe other things I should address
-motor mounts and stabilizing- currently stock and broken
-throttle/oil cables- currently work, but will most likely brake when doing the motor mounts
-vents for plastics- need side panels with all tabs or way to secure


I am also looking for other quality parts in good condition since my '05 has 5,400 miles primarily stock, and I am not sure what the current owner did for work on the engine. Any other suggestion is also welcome since I am most likely forgetting something that is needed to be addressed.

 

[SnowScooter]

Did you ever get any answers on this topic?

If no here are my suggestions...

Fuel filter - high performance engineering
Motor mounts - high performance engineering, compfusion, or a dealer...just order 06
model mounts
Cables - Motion pro makes an aftermarket, but you will have to call to inquire as
they are special order. Its both cables in one and around 45 bucks.
Vents - SLP has a good variety of venting

If you do motor mounts, add a torque link and push arm from SLP also...they are almost necessary on the fusion. Also check the condition of the stock bump stop on the clutch side as it is probably destroyed. If you havent balanced the clutch, indy dan can help you out there...he did a great job on mine.
Also suggest removing the dead loop in the coolant system, requires a few hardware store parts, but helps greatly reduce trail running temps.
As for the fuel filter, buy the cheap tool lisle offers to remove the fuel lines...they work great.
And good luck removing that engine...Im working on mine right now...what a PAIN. Basically have to remove the seat and tank to get it out.
And definitely look close at your throttle body boots...the stock ones cracked. Make a heat shield or put heat tape on the new ones.

A side note, check your vin with the dealer to see if and what updates were done...there were some recalls.