Hey guys I am new to the forum and I currently got a killer deal on a 900 with a bum motor. It is the 05 and it chewed a piston, cylinder,rod bearing, and crank bearing on PTO side. I have worked on a lot of cars and motorcycles, but not too many sleds. I am going to get the updated crank/clutch kit and 06 pistons I was just curious on what I can do about the case. The case has a pretty decent groove where the bearing wore. I was just wondering if a shop can clean this up and I can get the next size bearing like a car or if I am stuck getting a case as well. I got the sled pretty cheap so doing a complete motor won't hurt my budget too bad. I am taking everything to SLP tomorrow morning to assess the damage but I was just curious about what you guys think. Thanks in advance for any input.
New Member First 900 rebuild
- Thread starter JeremyR
- Start date
send the crank and cases to indy dan at indy specialityies for a TM1, and the primary clutch for a balance/spring job
send the jugs to milliniem to get re-nic'd
order 06 pistons from the local dealer, along with bottom gaskets, o-ring set for the head, VES gaskets
install all IAW the manual
when re-installing motor switch out the old motor mounts for 06 mounts
alaing clutchs and set for a 115 belt
add FBF (or motion pro) throttle/oiler cable
re-route collant lines into a single loop, instead of the hybred twin loop it has now
premix 1oz/1 gal two stroke oil in the tank
break in motor easy...after 100 miles feel free to hammer on it
and start reading the stickey's....alot more things that can be done to make it a fun, reliable arm jerking smile maker!
send the jugs to milliniem to get re-nic'd
order 06 pistons from the local dealer, along with bottom gaskets, o-ring set for the head, VES gaskets
install all IAW the manual
when re-installing motor switch out the old motor mounts for 06 mounts
alaing clutchs and set for a 115 belt
add FBF (or motion pro) throttle/oiler cable
re-route collant lines into a single loop, instead of the hybred twin loop it has now
premix 1oz/1 gal two stroke oil in the tank
break in motor easy...after 100 miles feel free to hammer on it
and start reading the stickey's....alot more things that can be done to make it a fun, reliable arm jerking smile maker!
Thanks for the reply. From what I have heard the TM1 is the only way to go. The whole thing that started this was the piston started to peel the top of itself and filled the case with shavings which chewed everything else. Is this common in the 05? I'm excited to tear into it. It looks like the 900 has a love hate relationship. People who aren't afraid to wrench on them love them but others hate them. I don't mind being greasy so I'm hoping to be tearing it up here shortly! If the one jug is fine do you need to re-nicasil it or can you hone it and clean it up? sorry again haven't worked on sleds much so I am not sure of the procedure.
think of it like a V8
would you only hone 1 cylinder, and then stuff new pistons in all of them?
get them BOTH done, so they are VERY close in tolerance
be very careful with the wrist pin c-clips...they shoot out and get lost pretty easy
with a TM1 and 06 pistons you'll have elimatated 85% of the engine related problems......06 mounts will cure another 10%
clutch alaingment is the last part
if you dont liek the 06 mounts, go with a billet crossbar from franz, and mounts from compfusion.....it WILL have alittle more vibratation at idle this way
I think its franz who makes a stellar billit alum chain case cover too....another must.....the stock plastic one warps and will loose oil
rider select delete is another great option....lose wieght, and a system that never seemed to work on my sled
when running right, a stock 9 will even put a smile on a turbo guys face!
would you only hone 1 cylinder, and then stuff new pistons in all of them?
get them BOTH done, so they are VERY close in tolerance
be very careful with the wrist pin c-clips...they shoot out and get lost pretty easy
with a TM1 and 06 pistons you'll have elimatated 85% of the engine related problems......06 mounts will cure another 10%
clutch alaingment is the last part
if you dont liek the 06 mounts, go with a billet crossbar from franz, and mounts from compfusion.....it WILL have alittle more vibratation at idle this way
I think its franz who makes a stellar billit alum chain case cover too....another must.....the stock plastic one warps and will loose oil
rider select delete is another great option....lose wieght, and a system that never seemed to work on my sled
when running right, a stock 9 will even put a smile on a turbo guys face!
