Ok guys.... I was a polaris guy until about 2 years ago, I have since switched to cat and currently own a firecat. I was on of the diehard Storm owners, stop laughing...

Anyhow, back to my question. I picked up a 96 Ultra SP for under a grand and its mint only has about 2500 miles on it and has been ridden 2 times the last 2 winters. I know this sled was a terd from the factory so what do I need to put in this thing to make it a fun backup sled. Clutching, jetting or what. No pipes!

Can I make any upgrades to the suspension to get a lil better ride out of it?

Any input would be appreciated.

They are nothing without the pipes. 103 hp trying to breathe through the single. 145 with the twins. All the clutching and jetting in the world isn't going to make a 103 hp 680 fun IMHO. :zzz:

First is the sp aggressive or wedge chassis? I know you don't want pipes but tripple pipes are the only thing that will make them run. If it is for tuning and durability reasons that you are avoiding pipe then you could use the factory pipes from an Ultra SPX. It must be aggressive for it to work. Then with some clutching and getting the thing will fly. As for the ride, extra 10 or extra 12? What are you trying to make it do? If you want smoother ride and its extra 10, install PPS shock. Currently $119 from your dealer. If equiped with fox shocks get the remaining shocks rebuilt. You can visit my site if you are interested in getting them rebuilt. www.jbshocks.com

The SP is a wedge. Like I said, I just want this to be a spare, I dont need triple pipes on this. There has to be a good clutch set up for a stocker and I know it was fat from Polaris like all the other sleds, just want to know what to set it up like since its old and the information line has moved on to better sleds. Its an x-tra10 skid. The PPS shock's are that much better?

I would start in the clutch. Look at what its got for a helix in the secondary. It might only have a straight 45 degree. My '99 700 XC SP came with that from the factory and it slow off the line.
You could try putting in a dual-angle or a tri-angle helix and that might really wake the thing up. Maybe like a 45/36 or something like that.
Id stay away from triple-pipes. That sled is noseheavy as it is, you dont want to add more weight to it.
Hebi

Jet the mains down 2 sizes from stock, this is good to -30C. Lean the pilots out to the same size as the 97 ultra sp, have a dealer look it up for you. Check the clutch alignment, and set the engine torque stops tight to the engine and motor mount strap, no air gap. Remove the windage plates from the secondary clutch. I would gear down as well, as they came geared way to high from the factory. Go to 21/39, or 21/38. For clutching, a hot seat white primary and secondary springs, a HSP36S helix hole #2, and hot seat I-1 weights (53.2g). Use a 3211066 belt, and have the primary clutch belt to sheave clearance set to .010" to .025". A set of higher compression heads from hot seat or SLP will give it quite a bit more snap, but you will then have to run 91 octane only. Use BR9ES or RN2C plugs only as well. There were a few bulletins as well on that sled, for a jackshaft bearing kit, different suspension mounting bolts (like a 97), an oil tank extra vent line, and to make sure the oil light sending unit float was pushed all the way into the tank. The secondary clutches also had a chunk of casting flash, by the spring hole in the moveable sheave which could cause the spring to pop out, and it needs to be removed. Also verify the usual carb and oil pump sync, and the proper air screw and needle settings.

cluthing/gearing/jetting was pretty good on the '97 sp.
if you are only going to use it as a spare, set it up like the '97.

if you want it to really go, you'll definately want triple pipes and lots of studs.

:banghead: Hello i my self own a 1996 Polaris Ultra 680 I dropped the mains down to 320s 0 to 3000 feet I found a really good trails setup was to run a Polaris Almond/Red Primary spring 165/310 Polaris 10A weight's 55 grams Polaris R12 Proggresive helix 50/36 with a Polaris secondary Silver/Blue 42/75. Run 20/35 gear setup 1.75 ratio. Take out the air horns from the top shelf of the air box. Buy a engine brace engine likes to break motor mounts and it helps keep the clutchs lined up correctly. HAVE A GOOD SEASON

the pps is a huge improvement in ride.

Thanks all this is good info.....