I'm betting the build cost between an 850 and a 9R is very minimal. Just like in every product line they build Polaris focuses on the top end models because that's where the margins are. Look at the poor 550 fanner. Polaris is the only one still using such old tech as far as I know and it looks like it will be that way for awhile. I love my 850 NA but all of my smaller sleds ( utility, kids ) are all slowly migrating to Doo. It drives me nuts to still be choking engines and smoking the hell out of the neighborhood when starting one up cold at home. I still have two Voyaguers and one Evo to replace then I am done with Poo's old tech and moving to another brand. That also means that all my grandkids are going to grow up riding Doo.
Could you buy a Pro 600 and put the EVO seat, tank, and bars on it? For the price of an EVO, I'd probably buy and older sled and mod it to fit the rider - if I had kids. Still, the 550 is a good motor if the power level is where you need it (and most kids don't need more). I still love carbs, especially on a cheap yard sled. They can sit for five years - drain the gas, take the carbs and fuel pump apart and clean them, and they run like new (if they're not rusty). You're probably replacing half the fuel system on an EFI sled if it sits that long. If I ever have a kid and he/she doesn't want to learn how carbs work and won't ride a sled with them, I'm disowning them. Still, Polaris could easily offer something like the Doo 600 - just use the 600 CFI as a basis, drop the VES, and simplify as much as possible.
Anyway, a lot of the early 850 failures were from a blocked oil line, and I can't believe that's still happening. They must have chimpanzees running the assembly line. Even IndyDan had a lot of praise for the 850 when it came out, and every indication is that the design really is pretty good. Some people are getting tons of miles out of them, but it's unfortunate some are still blowing, and because of unforced errors (lack of QC). Someone here was talking about the old days when some guys would tear a brand new sled apart and re-assemble it - partly to tweak it, but also to find and fix assembly errors. It might be time to go back to those old ways... Now, why can't Polaris just offer a snowcheck option where you get a crate of parts and put it together yourself?
