My 900 Mtn. Cat build (after totaling ot out)

[PowderCrew]

Fall of 2009 I finally had a lil' dough saved up and bought a stock '03.5 900 1M.

A little impatient for snow, wiped out one side of the front suspension on a HUGE boulder on my 3rd ride of the 2009 season...

 

[PowderCrew]

Got her fixed and was able to put 150 miles or so on her, but was fighting an issue with the motor randomly "cutting out". Thought I ALMOST had it licked, when she cut out at the top a big hill while sidehilling above some timber. Rolled 2 times, RAN ME OVER dead-center when it got to me after it found its track and got about a 30yd run at a 60' pine at the bottom.

 

[PowderCrew]

The front bulkhead was caved and the rear tunnel crumpled, so in the spring of 2010 I found a rollong chassis and began the rebuild:

The chassis had some unique mods that I'll get into later, that inspired me to "roll" with it instead of just swapping the motor and being done with it...

 

[PowderCrew]

The summer was spent swapping in the motor and replacing whatever parts needed replacing. (discovered the throttle position sensor was the issue with the "cutting-out" problem) I mounted my BETTERBOARDS and the next change to be made was the seat. Shopped around all summer and didnt find a BOSS I liked. At the Salt Lake Expo I came across a totaled out Dragon at the swapmeet and got the seat and tank for less than $115.00... and it fit NIIIICE!

Mounting the seat:

 

[PowderCrew]

Next came the "rattle-can" metallic orange paint on the steering post and FLY pivit risers & front suspension, new Simmons skies and aluminum rear wheels. The "unique" mods I mentioned were the FLY risers which put the bars up and forward without a forward-post kit... and "double-stacked" drop brackets in the form of SLED-JUNKIES on MOUNTAIN MAGIC brackets. (wasnt sure how that was going to work out?)

 

[PowderCrew]

fix

 

[PowderCrew]

I decided for the season to go with the LEXAN hood that came with the chassis. Plan to but a stock hood in the summer and wrap it, but gonna save the $ for the winter. It already had a vent kit on it (though it was JUNK) so the hood was already cut. I met Tammy Schoen of 2COOL AIR VENTS (http://www.2coolairvents.com) at the Salt Lake Show and really liked the product. The price was GREAT so I ordered me a set. BEST VENTS on the MARKET!

 

[PowderCrew]

Now she was really starting to get me EXCITED about what I was getting done with her! So GRAPHICS came next. Didnt do much here 'cause as I said... the hood will be going into retirement. decided to "REPRESENT" the sled crews from out west here as I've ridden and filmed with them and produce my own amateur films here in elko. Added a Sno-Bunjee handlebar bag to haul the cameras around in.

 

[PowderCrew]

Now the season is well under way... and the mods have continued. EDGE Powersports in Utah got me hooked up with a set of running board edges off the 2010 M-series cats. I wanted to cut the rear of the boards short to reduce the drag in deep snow. LOVE these things! Look and WORK AWESOME!!!

 

[PowderCrew]

And thats pretty much got her up-to-date. Added a "soft" tunnel bag thats actually used on mountain bikes to haul tools. Fit nicely and just velcros on with "footman loops". Can add the loops to my other 3 sleds then just transfer the bag if I ever climb on a backup. Currently... the steering post is WAAAAAAY too weak for how I ride. It CONSTANTLY is bending, the hoop being sloppy as well. Have plans cooked up to add a brace from the steering hoop over the motor to the front bulkhead kinda like a racecar. looking to cut the post and fill it with roundstock then re-weld it if I can find the right size stuff? And upgraded from a 9 tower to a brand new 6 tower.

 

[PowderCrew]

 

[PowderCrew]

Other add-ons include:

Dial-a-jets
SLP single with gutted box
V-Force 3 reeds
KOSO egt's
Cutlers helix

 

[sledmasterr]

Joe, you have that sled looking good, hope those clutch parts worked out for you, let me know if there were any problems...Brian

 

[PowderCrew]

6 TOWER upgrade Complete! SEIZED motor 50 miles later.... CHECK! Sled left on trailer 'cause shed is full of projects... this summer: CUTLERS 1000 kit. Gonna ditch the SLED-JUNKIES and re-store some of the factory geometery next season to see how big a difference there may be. No complaints on the "double-stack" as it was... just time to compare? "Rattle-paint" will be replaced with POWDERCOAT in Reno.

 

[Reeb]

Forward posts help in a huge manner in terms of steering compared to where it's at by lookin at the pics.
Or you could just sell me the motor as is!

 

[icr]

Or you could just sell me the motor as is!

And buy my union bay 1000cc ready to drop in.

 

[PowderCrew]

Forward posts help in a huge manner in terms of steering compared to where it's at by lookin at the pics.
Or you could just sell me the motor as is!

I looked into the forward post... didnt care for it. It moved me too far forward and, for me... my shins and knees were too close to the back of the hood and foot-wells. Kept banging my knees. I went with the 4" Fly Pivot riser and my rider geometery with the seat and tank in standup position is juuuuust right. The old sled actually lays over real easy for me. I ride very aggressive....

...so hanging a leg out for weight transfer and sidehilling puts the handlebars right where I want them.

 

[Reeb]

I was just thinking the handlebar movement would be ackward with the way you have them. Like they are swinging out?
As far as hanging my leg out there, I don't have to with my sled. Stay fairly neutral and flick it around A LOT easier than my Rev. (I know the people that'll gimme hell for that comment but.....)