Im looking for some info on a BIG BORE KIT hop up for my '96 XLT. I smoked the motor last weekend and nows the time for the upgrade. i would like to here from someone that has done it or knows someone that has. ive heard that the lower end can not handle the extra power? is this true. PLEASE HELP. thanks Eric
Eric. SLP has the only big-bore kit on the market for the XLT, but its spendy. In the $1500-$1750 range depending on options. Many people that I have talked to have broken a bunch of cranks using the 654 big bore kit. Your best bet is to bore your sled oversize, Wisco makes pistons up to .040 over and Polaris makes them to .020. With this small of an overbore the heads don't need to be modified and you don't have to worry about squish. Depending on how bad your engine is, that may be all you need to do. '96's were notorious for bad cranks. One of the best things you can do for this sled is to install a 4-line oil pump that lubes the PTO bearing directly. These pumps came stock on either the '97 or '98 XLT's. The cases have to be split to install it properly and thats a good time to replace the crank bearings. Mine cost less than $300 including the pump and the bearings.
my friends xlt went through 3 crnks in one season!! He got rid of it, i don't blame hime do you? The sled that i got for this winter is a 600 triple and i made sure that it had these bearing oil lines. A very worthwhile investment, unless of course you like down time. Good luck!!
it just so happens that a very good friend of mine has had a bigbore kit in his sled for about a year with very good success but i will let you in on a little secret about our horrible piston port engines i know a place were they have add a reed cage to the long block it includes heads also
oh by the way my buddies xlt spanks an ultra with a big bore kit