This is My 900, there are many others like it but this one is MINE

[SnoBusMan]

Hey Y'all, jus thatought i would post a thread on my sled and the "build" to get it to where I want it. It is a 2005 Switchback 900 (the orphan of the orphan 900 family) she is my black bitch and I have wanted a sled like this for a while. first off I'll put the specs of how she was when I got her. SLP cold air intake, 144" cobra track, radiator delete, redone rear suspension with fox shocks, front fox shocks, V force 3 reeds, still sussing out what else was done sinc I got her used. I found that the chaincase was leaking pretty bad so I decided to end my season this year. I have had the hot running issue that seems to be common, I also had a 5 check engine light flash issue that I think was a shorted wire (I am going through the harness now to see if there are other issues)

My Plans are to have IndyDan go through the engine and clutch to make sure that I have a seroius base to work with, The throttle/Oil cable replacement that seems to be top on a lot of peoples fix it before it breaks lists. I have to check the motor mounts to see what is there, The ones that are there right now do not look stock and if I have any luck the would be CompFusions (probably not with my luck) I am also installing a radiator in the nose that shouldwork with the intake I have, New intake boots should be done while the engine is out, I am thinking about gearing it down from the 25/37 to 25/41 just to get a little more useable torque. I also am planning on 2006 pistons for reliability. I also was thinking about adding A/C tunnel coolers in series to add more cooling to the engine in series with the rear cooler. as far as clutching I am unsure since most of the 900s here are longer tracks and you all ride in higher elevations with deeper snow and steeper (but not by much I ain't no flatlanduh) hills. I wil post some pictures if I you have any interest while I am posting.

I do have to say after searching and searching for answers on my issues I have almost always been led to SnoWest foriums for the best answers. Hopefully I can return the favor someday!

 

[SnoBusMan]

Ok well I did some poking around and I have a bigger issue than the leaking chaincase, I found that my primary clutch is cracked (see picture1) and that there is a broken bolt in the front engine mount crossmember. I also wanted to see what helix is in the driven clutch but the bolts for the helix are frozen and that will take time to remedy. Oh well at least I have all summer to work on it. I also put a couple of pictures if the front mounts if anyone can tell me what they are it would be greatly appreciated. the other pic is the leak I noticed at the VES valve it seems to be spitting out exhaust, Hopefully that isn't anything major. O well I guess I will be sending IndyDan a new clutch since I don't think that one will be used anymore.

 

[SnoBusMan]

Here are the other pictures

 

[guidoxpress]

Good luck buddy, hard to beat the power of a dialed in 900..welcome aboard the elite lol

FYI, you have COMPFUSION front motor mounts incase you didn't know...looks like the old version..the broken front crossmember bolt is very common with these mounts..broken quite a few myself..

Get a used clutch on ebay for cheap and send that to Dan for a full rebuild/balance..

Good luck in your journey and build

 

[SnoBusMan]

Thank you, I had talked to Colin through Emails before and he was quite helpful. I did think that those were his but wasn't sure, Do you know if the new urethane inserts will fit? Parts for the sled will have to wait a little since I am currently finishing my house, I will start the teardown though since I do have time here and there. The clutch was a major setback but at least it didn't grenade and cause me more issues. From the looks of the sheaves it was never really set up correctly. The ridge at the bottom that Dan talks about when discussing his service is pretty big and the cracks are definately from heat. After i got the secondary off I found that the screws that hold the helix in are frozen (Bummer) so I wil have to take some time to get those out.

Now for my current question, I am going to install a radiator (aftermarket) with the SLP intake, It is smaller but has a fan. What I am thinking is this: I know about the "dead loop" issues but I was thinking about installing the radiator using Y connectors instead of a T connector with the radiator in the straight section to the radiator and the angled from. this will creat a flow through the radiator but will allow the coolant enough time to cool in the radiator any thoughts? I will still have all the coolant going through the heat exchangers and not back to the bottle.

The picture below is the elbow that is in the thermostat line, I think that it is causing an obstruction in the coolant flow causing the hotter than norma temps I was seeing on the trails let me know if this is the same elbow that you have if you are running a radiator delete.

 

[Z-Man]

Radiator is not compatible with the SLP intake.

I have an elbow like that on my turbo it's not the problem the cooler is to small.

Before trying to but a clutch on ebay have indydan check your engine if you are going to do that. You need to know what size crank you have and if you end up having Dan do a TM1 crank for you it will come with a new clutch anyway.

One more thing, Nice coolant reservoir.

 

[SnoBusMan]

Oh You saw that huh? Funny thung about that, it was an experiment to see if my headgasket was leaking (it isn't) it's just a water bottle with a tight fitting hole in the cap to catch any coolant pushed out under load.

I agree that the rear cooler is too small but I havent heard from anyone about running tunnel coolers. The coolers I have are just a touch shorter than the tunnel protectors inside the switchback and I was going to run them in series. Any opinions?

The radiator I have was removed from a 900 RMK with an SLP intake so we will see if I can make it work. (well here's to hopin') if not I will have to make other adjustments. I do have scratchers and that just keeps it below the "limp home" heat range.

I have Talked to IndyDan on the phone and got a lot of input in the half hour I Gabbed his ear off, Pretty patient for a guy in the peak of his busy season Gotta give him a ton of credit there. I will definately be seding him my work as well as much word of mouth busniss as I can!

 

[SnoBusMan]

Ok i finally got the helix off and i cannot figure out what i have. Any ideas? I am sure it was a clutch setup from someone that didn't wast their "secret" passed around. It also has a yellow primary spring and an orange secondary Not sure who's though.