I am currently in the process of an engine swap where i'm puttin this 97 440 fan engine in a 95 xlt chassis and i was going to try and use the xlt clutches and gearing. I was wondering if it is possible to put the xlt primary on the 440. I have the engine mounted it the chassis and now i just need to get the clutches figured out.

that clutch will work on that shaft. but let me ask this....is that an xtra 12 chassis?
if it is youre asking for headaches. that chassis is way to heavy. your 440 fan motor doesnt have enough low end power to move that outta the corners, or be much fun. youre gonna be tuning your clutches all winter till you get it right. i would gear it way down, and also find a set of 11 wide chain and gears. youre gonna wanna lose every ounce of rotating mass you can. losing 1 pound of rotaing mass is like losing 7 pounds of stationary weight.
i understand being on a budget, but situations like this have lead to somepeoples drinking problems(lil humor in this reply!) but seriously seen many try similar projects before. good fun if yure just gonna beat it around with the kids, but not much of a trail sled.
let me know if you need anything, have tons of polaris parts. including a 95 xlt motor.
good luck

not an x-12 suspension. i noticed the chain is a lot heavier than the one in my sport.. maybe i'll swap the chain and gears out of the sport into that but my plan was to definately lower the gearing... its going to be my extra beat around sled and i wanted it geared down so it'd only go like 55ish.. it went about 70-75 in the sport chassis.

The swap has been somewhat of an adventure so far. The stearing stems had to be swapped out and the bulkhead was totally different so i couldnt use either mounting plate from the xlt or the sport. I ended up welding a piece into the bulkhead so i could move the stator side mount bracket over onto the pto side of the stearing stem. Then I put a small plate under the motor to mount the old xlt plates onto the motor and get it bolted into the sled. I wish i would have taken some pictures along the way but its too late now.

not too bad off then, if its just standars suspension. seems like a ton of work though. wouldnt it have been easier to buy another xlt motor? i love tinkering with one of my 6 indy sleds too, but i usually go bigger. would definately swap gearing out. if you need anyparts i have tons of parts for indys.
good luck with it, its all about having fun!

Its all about tinkering thats for sure.. My sport chassis had a bent tunnel, hole in the bulkhead where a fenc post went through it, totaled suspension and track. The xlt is in nice shape and since i had this motor just sittin there i thought i'd try to throw it in here and hopefully make one sled out of the 2 for little or nothing. I have a 99 mxz 670 ho that is my usual riding sled and this 440 was just my first sled from when i was 13 that i will hopefully become the g/fs sled just to come ditch banging and mess around with. Not plannin on puttin a whole lot of miles on it when its done really.

Not trying to hijack your thread but bigwedgies do you have a good clutch for a 95 XLT Special?

well i got it finished up today... got the suspension back under it and the chaincase sealed up.. now i just need some snow so i can do a little fine tuning on it... took it for a spin on the pavement and it seemed to pull a lot better than it did in the sport chassis.. lifted the ski's off the ground and didnt feel nearly as boggy... right now i have the 440 primary on and the xlt secondary.. just need some snow so i know for sure what clutching i'm going to go with.