975 build part 2 what am i thinking

BIGGDAWG · Oct 24, 2010

Well I am at it again guys. i just wasn't happy how i had everything fabbed up to make the 06 motor fit the 05 chassis.

so i am doing a full 06 conversion on it. and no it isn't a direct fit lol.
i am putting an 06 fusion bulkhead on my 05 tunnel here are a couple of the pics. the drive shaft is moved back 3/4 inch on the 06. will have more pics tomorrow i have it assembled up to the steering hoop and foot rests.

i modified the 05 foot rest on the right side and bought 2 of the 06 footrest pieces for the left. the clutch is down and back and gets into the foot well.

mountainhorse · Oct 24, 2010

Heck YEA!!

Keep us filled in Bruddah!!

What did you use for rivets?

wayne+garth+waynes+world+158345391252694788.jpg

BIGGDAWG · Oct 24, 2010

mountainhorse said:
Heck YEA!!

Keep us filled in Bruddah!!

What did you use for rivets?

i used polaris rivet #7661637 pop rivets they were used on the gen 2 chassis for putting tunnels on. i did a bunch of them and i used the hammer rivets 7661837 on the chain case side so the rotor had clearance.

just some fyi the complete drive line is diff between the 05 and 06 here is a small list.

chain case
jack shaft
drive shaft
steering column and all associated mounts
oil tank
coolant tank
brake rotor
coolant hoses
ecu bracket
oil tank bracket
bulkhead
both right and left foot rest assemblies-- modified the right one with sawsall replaced 2 of the three parts on the left one and modified the most expensive one.
steering hoop -- modified mine to work -- made and welded on bracket for oil tank

all in all not really worth it should have just built the 975 as an 05. :face-icon-small-dis
but i wanted it right so i am doing it right it is only money. lol

BIGGDAWG · Oct 24, 2010

a few more pics. this is where i am at now by the end of the week it should be a roller.

waiting on a custom billet front motor mount cross member i am having made and some hoses before the 975 will go back in.

05900 · Oct 24, 2010

Wow that's dedication!! Good Luck and Better snow.

BIGGDAWG · Oct 26, 2010

Getting quite a bit done. body work is on and i am installing the wire harness. tomorrow i will do the track and rear suspension and handlebars. coming along nicely.

BIGGDAWG · Oct 27, 2010

It's a Roller!!! Well i am just about done as far as i can get till i get more parts.

i got the bars on tonight and installed the track and suspension. the iceage rails look great.

I sent my injectors of to whitchhunter performance to get cleaned and flow tested that will take a week to 10 days, i ordered my armorcord for the recoil, and my front billet motor mount cross members should be done this weekend. So in 2 weeks with some luck it will be done.

diamonddave · Oct 28, 2010

Way cool man. Every 900 owner should tear one down this far to get some insight into what makes them click. To all who believes your 05 is better than my 06....If this is true, why would BD be doing all this work>??

05900 · Oct 28, 2010

Cuz 4 injectors are 2 many thats why! Does it mean a fusion is better than a RMK also?
ha ha aha aha ha ha ha:hippie::rofl:

mountainhorse · Oct 28, 2010

Dave...At the 975 level... I didn't notice any diff in the power of the 2005's compared to the 2006's... both with 975's in them.

The other refinements like lower rotating mass of the secondary and lower angle of pull on the secondary plus a much shorter/lighter chaincase... those were some key items.

The 05 spindles stink...but at this level of build that is a moot point.

I liked the more expenseve roller chain tensioner of the 2005's ...

That sled is SUPER nice!!

BIGGDAWG · Oct 28, 2010

mountainhorse said:
Dave...At the 975 level... I didn't notice any diff in the power of the 2005's compared to the 2006's... both with 975's in them.

The other refinements like lower rotating mass of the secondary and lower angle of pull on the secondary plus a much shorter/lighter chaincase... those were some key items.

The 05 spindles stink...but at this level of build that is a moot point.

I liked the more expenseve roller chain tensioner of the 2005's ...

That sled is SUPER nice!!

I am going to use my roller tensioner instead of the 06 tensioner. What were they thinking?

thanks for the comments guys.

BIGGDAWG · Oct 31, 2010

only making slow progress waiting on parts and pieces. I finally got the billet front motor cross member from my friend.

here are a few pics of the billet mount and my 09 sway bar mounts that i made up. not perfect but will work till i can get my new a-arms. also a pic of my battery mounted i use it to prime my fuel pump and power the ecu so i can set the tp on the power comander 5

make note in this first picture i notched the compfusion mount. i noticed when i took it apart that the steering linkage was hitting the mount. something you all should check that are running compfusion mounts

diamonddave · Oct 31, 2010

mountainhorse said:
Dave...At the 975 level... I didn't notice any diff in the power of the 2005's compared to the 2006's... both with 975's in them.

The other refinements like lower rotating mass of the secondary and lower angle of pull on the secondary plus a much shorter/lighter chaincase... those were some key items.

The 05 spindles stink...but at this level of build that is a moot point.

I liked the more expenseve roller chain tensioner of the 2005's ...

That sled is SUPER nice!!

I wasn't talking about 2005/2006 975's....I was talking about the massive difference in how the 06 900 SLEDS behave, handle, etc. compared to the 05's. There's no comparison and that was the point I was trying to make. Not that 2 injectors more are any better. BD already had the 06 975 MOTOR last year so my comment above would have been a moot point and not made sense if the 06 975 MOTOR was what I was talking about.

I'd rather ride a bone stock 06 with steel shocks than a HOLZ/FLOATED/SPINDLED 05.

mountainhorse · Oct 31, 2010

Gotcha.

ghostwhite · Oct 31, 2010

diamonddave said:
I wasn't talking about 2005/2006 975's....I was talking about the massive difference in how the 06 900 SLEDS behave, handle, etc. compared to the 05's. There's no comparison and that was the point I was trying to make. Not that 2 injectors more are any better. BD already had the 06 975 MOTOR last year so my comment above would have been a moot point and not made sense if the 06 975 MOTOR was what I was talking about.

I'd rather ride a bone stock 06 with steel shocks than a HOLZ/FLOATED/SPINDLED 05.

Way to ruin my ambition,:face-icon-small-fro time to find an 06 :face-icon-small-sad

Guess its time to give it up and work on my new 4x4 :tea:

BIGGDAWG · Nov 1, 2010

Got my injectors back from witchhunter performance shipped them out on the 27th and got them back today that is service would highly recommend here is the data sheet

got my new mount installed on engine and replaced my pull rope with armorcord

BIGGDAWG · Nov 4, 2010

got the motor in and all hooked up should have it running sunday. :face-icon-small-hap

Danbot · Nov 4, 2010

She's coming together now! That front mount bar looks badd a$$. Was the original filled and welded, or is it a custom piece from scratch?

BIGGDAWG · Nov 4, 2010

DiscoDan said:
She's coming together now! That front mount bar looks badd a$$. Was the original filled and welded, or is it a custom piece from scratch?

i had a friend machine it from billet aluminum the stock ones were breaking this one shouldn't

ghostwhite · Nov 4, 2010

I believe they are custom from scratch, I want one NOW but I will just wait till mine is f'd and if the billet version is still viable.

Looking good BD!

975 build part 2 what am i thinking

Well-known member

Well-known member

Well-known member

Well-known member

Embrace the BRAAAAAAP!

Well-known member

Well-known member

Chilly’s Mentor

Embrace the BRAAAAAAP!

Well-known member

Well-known member

Well-known member

Chilly’s Mentor

Well-known member

Well-known member

Well-known member

Well-known member

Well-known member

Well-known member

Well-known member

Similar threads