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Discussion Starter #1
I LEAREND MY FRIEND'S 2005 POLARS FUSION 900 BLOW OUT BY BAD PISTON AND TEAR MOTOR DOWN AND SHOWED PCRANKCASE BOTTOM HOLE AND HEAD CYLINDER DOME LOTS NICKS MARK AND BAD CRANKSHAFT'S ROD BY PISTON SHIRT BROKE CHIP CAUSE :whatever:

FOUND POLARIS PARTS FOR 2005 and 2006 900 cc piston showed:

polaris number 2203098 from 2006 900 piston (replaces 2202811 from 2005 900 cc piston)
THAT WHY POLARIS WON'T TELL US OR WON'T RECALL???

HIS SON AND I WILL TEAR HIS SON 2005 FUSION 900 AND MINE 2005.5 SWITCHBACK 900 AND REPLACE NEW PISTON (number 2203098) to save $$$$$ without damage everything with poor piston too thin wall cause broke chips and crack..

I SUGGEST REPLACE ALL PISTONS YOUR 2005 POLARIS 900CC.

SEE PICTURES:
 

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I am just curious as to whether it is a skirt that is to thin or is the piston just to small for the cylinder and caused slapping which in turn broke the skirt. I seen one on the trail and at an idle you could really hear the piston slapping against the cylinder, I do beleive it was an 05 also.
 

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Skirt breakage is a sign of too much piston/cylinder clearance
 

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Discussion Starter #4
My friend and his son and I tear down our 2005 Fusion(4,500 miles) and my switchback(2,800 miles) 900 motors last nite and found my 900 switchback 900 exhaust port show crack hair or nick hair.
see pictures.
My friend's motor blow out and he said NEVER over 175 Temp since his new sled.

I will get new pistons from 2006 900 cc and will measure thick wall piston shirtcompare our old piston shirt then I will post ..
 

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