I thought I'd start a little progress thread for my XL.
I have quite a list of things to do & a small budget to get it done.
That being the case, Pleas don't expect too much too often.

So... First off so far

I borrowed Bearfoot's idea for the breathers.
I also made spacers to reduce the 1.5 bore down to 1 1/4.
I added an oiled foam wrap & pre-filter over the gauze filter they came with.



Here I ditched that useless K&N thing Redline gave me for something that actually works.
I got the UMP filter system for the Polaris RZR & made my own mounts to get'er all mounted up.
I'm still in the "fitting" stages as these photos were taken.
The aluminum mounts are actually lighter than the "stock" steel bracket that came with the filter assy.

I'll post up the final install when I get it done.



Update 12/22/2010

Final mounting.


Added the plumbing.



Intake port
Please excuse the plumbing of the oil res. Thats just a fitment sample for the aircraft fittings.


Comparison between the stock corrugated radiator hose & the new system.
2-1/2 inches all the way to the box.


That should finish up the air box part.

nice..........

any other mods yet?
keep them coming...

Where did you get the hose from? Is it all 2.5in?

I put on a Gibson exhaust.
Not too thrilled with the system.
Ill show ya why...

I got the hose, & aluminum tubing the hose is clamped to, at Kartek in Carona CA.
Yes it is all 2.5 until the air box then it reduced to 2"
Kartek Off Road Parts & Accessories - Where Off Road is On!

I installed the Gibson exhaust.
I expected more but I got less.
I will admit, the sound is excellent. Nice strong throaty bark!
But...

This pic shows how the system didn't line up on center.
I did everything in the book to get it on, or close, to center. But that led to other clearance problems.
Too much pipe length here & there.
However I bent the lower support, the mid pipe would either hit the head, header or hit the gearbox.
Now... if it is for proper power output (tube length), I'll give them that, but it could still line up on center & be further away from the motor.


This pic shows how far off the spring retainers are.
Geez... not even close.


This pic shows how close the Midpipe is to the valve cover.
Header wrap is a must.
the lower mount was retarded as well.
Total hack job.
I had to die grind it to smooth it out, cut 1/2" off the top, It was too long.
Then I mill cut the lower bolt hole (cut the weld out & back) so I could get the nut on it & a socket to tighten it down.


This pic shows an aluminum seal seat I had to make for the back of the muffler.
Either the hole in the muffler was made too big,or the head pipe flange was made too small.
As well as them wanting to use the stock seal, no biggie if done right.
If the muffler was ever so off of a dead straight alignment, it would punch right through the back of the muffler. It happened twice during spring install.
So now with the seal seat it can move around all it wants & it will stay sealed.
Anyone without a lathe would be S.O.L, having this kit as it was sent to me.


This pic shows the muffler mount.
Not too much thought put into it.
A little to "automotive" for my taste but it's not a show car.
Effective & functional I suppose.


This pic shows the oulet, less spark arrester.
Gotta get rid of the button head screws & replace them with some safety wire-able flange bolts or cap screws.
These are just gonna strip out or fall out.


I'll keep it for now.
Just gotta test it & see how it holds up.
It does sound good.

This just goes to show ya, Never order something around the holidays.

XRMikey
check your pm

Update.
I pulled the gear box for inspection & a "Trouble" bearing change.

I found a damaged reverse gear. (happened at the dealer )


So I massaged it some.
It's not as strong, But I think it will hold up.
I just can't Pin it in reverse!


I also added a second vent port.



I also deburred & smoothed all the gear teeth & installed the new bearings.

Hi, Names Mike.. I came over here from the RZR forums, I am just amazed at the quality of your build.. I PM'd you a question about the mounts you built..Its going to cause quite a buzz over on RZR As a fellow UTV'er, Just wanted to say thats a wild badass machine! Feel free to come over to say hi on our Forum, I go by the same name.. Just not a newb over there I will be hanging around as I am moving down from Alaska this summer and wouldnt mind checking one of these out...Cheers, Mike

Update 1-25-11

I jumped to the front.
I pulled the steering box for some wear resistance work.

After disassembly I machined .0625 from this area where steel rides on aluminum.


Then I machined a piece of .0625 M1 tool steel & installed it as a wear plate.


I also made a wear plate for the top out of 1/16" Fiberglass reinforced Teflon.
It's supposed to be highly wear resistant. I'll have to wait & see.
I also replaced the weak stainless button head screws on top with some longer Flange-Head 12.9 Alloy Socket Cap Screws.



Then when I reinstalled the box I actually looked at the steering shaft a little closer.
Thats when i noticed the U-joints were off time by 45 degrees.
I guess thats one more project to add to my list.


The more I look at this thing, the more I realize that who ever built this car, Must of been in a hurry.
The front main tube is way off square. the front shock supports are un even.
I noticed in the back the rear down tubes are about 5/8" off from each other.
Theres miss matched fitting tubes all over this thing.
But... It sits square. I guess it's a good thing. I wont feel so bad when it gets hammered.