Polaris Xp900 Build And Engine Swap

crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
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I blew up my turbo 800 for the final time and was going to put a Hayabusa in it I had. After a series of event the plan was changed I sold the bus a and ended up with a 2011 xp frame that was changed because the a arm tabs where oval from a wreck. I also bought a 05 RX-1 engine from a salvage yard with a built engine and turbo kit. This is the carburator model but I got a good deal and it should still run strong. Here some pics I took along the way. You won't see anything spectacular here just making stuff work on a budget.


I started with a Racer tech gusset kit. I guess I should have taken a before pic. But here it is welded.


I took the apex wiring harness apart and cut out the stuff I didn't need. I also lengthened the wires that needed to be by soldering and shrink wrapping all the conections. The harness was the spiral wrapped and taped with good tape.

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crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
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Redwood City

The clutches were ordered so the engine and transmission could be lined up.

The rubber mounts were removed out of the engine and solid motor mounts were installed.


With wood shims straps and Big Dog the engine and transmission with lined up to create a bracket.

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crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
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Redwood City
Pardon my piece of crap garage and back yard we bought this fixer upper and the garage is last on the list.

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crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
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Redwood City
View attachment 12198
Bought a Cognito sway bar for it.

View attachment 12200
View attachment 12201
I bought a set of WER shocks off a new xp4 from a desert racing team. We had to move the top mounts out to make room for the engine. We also moved and gusseted the trailing arm tabs.

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Attachments

crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
120
63
49
Redwood City

Attachments

crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
120
63
49
Redwood City

Attachments

crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
120
63
49
Redwood City
I'm missing a bunch of the progress pics and it taken me awhile to get this far but it's almost ready to start.

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GOVACHO

Active Member
Nov 8, 2011
1,025
12
38
Riverssippi
Steve great looking build buddy cant wait to met up and ride one day. With that being said, if you ever get to tinkering and want to build something I would luve to get my hands on a copy of the belt shroud..
 

crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
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Redwood City
GOVACHO the thing is its a one off piece I made with a cardboard template. It would not fit yours because they are diffrent engines and if they were the same, your brackets would have to be identical to mine in order for it to fit. I know Mark could whip you one of these out with his eyes closed. I bet he wouldn't like how heavy it is thought. Lol I didn't weigh it but it's not as light as it could be. I think 1/4" aluminum may be strong enough and allot lighter. As you can tell I like building stuff beefy. I don't know what I did with the motor bracket pics but it's super strong. 1"x1/4" wall tubing all gusseted.

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Timberdog

Member
Aug 23, 2010
83
1
8
Can't go wrong with a dirt wheels magazine...:) I'm curious as to what hp you think you're going to make and the final weight of the car will be. I'm guessing it will definitely haul the mail, great build, thanks for sharing.
 

crazywatson

#13 - UTVUnderground Approved
Jul 30, 2009
1,272
120
63
49
Redwood City
No new pics yet I haven't had any time lately. Not sure on the weight and hopping to be a little over 200 hp

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