Hi All,

I decided our Trail Boss needed some attention so this past weekend I tore it down for a THOROUGH scrubdown and inspection.

It's my wifes quad and it's been ridden by a few relatives and freinds along with a few crashes by just about everone who's rode it so I had to replace some parts etc.

Anybody know the valve clearances for a 2001 TB 325?

Where are the timing marks?

I replaced the plug and the belt, straightened and refinished the steering stem, replaced an a-arm and tie rod and cleaned the air filter(normal maintainance stuff) etc.

What's up with the design of the lower steering bushing? Mine is sloppy. Any idea how much they run or will just drilling out the rivets and replacing them with nuts and bolts help?

Has anyone just hogged out the airbox lid and upped the jets?? The exhaust seems to flow pretty well and has a large outlet so I think there's alot to be gained by putting in a K&N with some airbox mods and jetting. If you have shoot me some jet sizes, the stock main is 142.5 I figured moving up to a 147.5 and 1/2 turn more out on the pilot would be a good start with the above mods. LMK

Banzai !!!!!!!!!!!!!

After tearing into this quad I know why it only costs $3k compared to my Raptors $6k I hope build quality is better on the Sportsmans.

 

I can check my manual for the 2000, should be the same. If no one answers by the time I get home, it'll be about 8:30 CST, I'll post them.

 

Intake and exhaust clearence is .006 (.15mm). TDC is acheived by aligning the "T" with the pointer in the timing inspection hole. The cam lobes should be pointing downward. That is from the Polaris serive manual. Mines been rolled, treed, jumped, dunked and caked. Total repair costs, 270.00 dollars. Doctors bills, well I could have bought 4 Predators.

 

Thanks Scootergptx!!

Where's the timing inspeciton hole? Under the belt cover?

I see in your sig your getting the RCR stage 1. What's the cost on that? Do you have a link?

Thanks,

Banzai !!!!!!!!!!!

 

Timing inspection hole is usually on the recoil housing (where you pull start it).

 

What's up with the design of the lower steering bushing? Mine is sloppy. Any idea how much they run or will just drilling out the rivets and replacing them with nuts and bolts help?


hmmm mines pretty sloppy to and it looks like its the rivets are stretched. i didnt mess with it yet but check out www.partsland.com they got almost everthing for your quad if not everthing

 

Replace that cheap plastic lower bushing with an aluminum one form HPD or Hot Seat. They are MUCH better and tighter. Mine required the holes to be enlarged slightly because the new bushing used nutds and bolts to hold it on instead of rivits

 

i need to replace it so ill check there i need to replace the upper ones to

 

Ritter Cycle
325.00 includes shipping. Call and talk to Rick. You'll see his name on these forums alot, and it has always been good. I'll definitely let you know how it works out. I ordered a new belt from him too, figured it's been through enough to need a new one. I've heard changing the belt can make a difference too.

 

Scooter,
I definately noticed a difference when I put on the new belt!!!! And it was super easy. No special tools needed.

I backed it up in my driveway, sat back on the seat and hammered it. It actually pulled the front wheels off the ground. First time it had ever done that.

I've still got to do the valve clearance but I'll let you know how that helps out. I know it makes a noticable difference on my Rappy.

Banzai !!!!!!!!