OK, so after riding the triple picklefork brand since 98, I decided to follow my sled instincts. Been an AC (sled)man since 72. I bought a 04 650 holdover and decided to see how it stack up against the Yamahammer. One trip through "The Tidal Pool" put my beloved Kitty on CPR. (NO ONE gets out alive!)The bike rocked a bit and the tank went under water for a second. Ingested water into the breathers for the clutch. Belt slipped BAD, but thankfully the bike runs great. After pulling the clutch cover off, there is the residue from the belt and swamp water mixture all over. I cleaned the clutches best I could, reassembled and installed the winch. (Deal I had with the dealer) The clutch cover seal was rolled, so perhaps that is where the water came in (?). Anyways........ I have a list of questions you guys could probably help me with.

1.) How do you lock up the tranny to get the driven clutch off? Reverse threads, right? Having done sleds all my life , pulling the clutches are not a problem. Or is there a spanner wrench to hold the driven? Reassembly procedure with the belt switch thing? (Darned electronics!)

2.) Is there an on-line manual? Or schematics?

3.) Belt deflection spec?

4.) Planned on taking (1) .8mm shim out. Will I REALLY need the EPI black spring? Heavier springs only help with backshifting, unless the clutch pins are weighted more. (Sled clutching) I may go to 27" Mud Bugs

5.) 27" Mudbugs Are these 6 ply tires? How are they on hardpack? I ride through forests and occasionly hardpack. Many tree crossings and HUGE mudholes. If you aren't getting dirty and busting things, stay home and knit! Think these tires are the right choice? Or a better suggestion? The stock tires make this thing push like a grocery cart in the corners! (Yeeuuck !!)

6.) Dyna will be here tomorrow morning, so Limp Mode will be a nightmare avoided.

7.) Anyone have experience with AC's fix for the 2 exhaust screw that BRAND you? Or do I need to make an aluminum shroud?

8.) Has anyone had a problem with the winchplate bending, causing the winch to mash the radiator? Its AWFUL close to the screen! (.125")


Thanks

Jeff

 

hey whats up .you have alot of stuff to be answered i might be able to help you with the belt deflection specs. well i have a manual for a prairie 650 which is the same motor/tranny and the belt deflection specs are; standard 22-27mm or .87-1.06in .they say when you use a straightedge on the belt dont push the belt more than 59n or 13lb to check deflection.[img]i/expressions/face-icon-small-smile.gif[/img]

 

I grab the secondary clutch with a TRA clutch holding tool that I "modded" with a notch in it.....still works for the TRA.

Removing the shim is the biggest thing you can do for the clutching, but if your going for larger tires and you like mud a lot, you will appriciate the faster back-shifting of a stiffer spring. I have the EPI black and the red secondary springs. The red is MUCH longer and therefore applys much more tension. I ended up staying with the black in the secondary as the red seemed to leave the engine in "low gear" much longer and let revs stay high even on long trail cruises......nice for power but made mileage very bad. With the Dyna module helping the bottom end, the black spring works great. Your clutch tension is set right if, after the belt has 100 miles, it squeals slightly when left in gear (stopped) for more than 5 seconds.....slip it into neutral and live with the squeal.

Branding-screws apparently have been rectified with a recall from AC.

My winch gets used a LOT and has yet to flex or move.

 

ok quickly before i go to bed i have heard of people apply high temp silicone to the screws to keep ya from getting branded and well my winch did go through the radiator screen on my 2002 500 i let a buddy drive it and he ran into a tree and caved the whole front end in but i wouldn't really worry bout it unless ya get in an accident i dunno if those tires are 6 ply but i highly recommend getting 6 ply tires like itp 589's or itp mud lite's once you get rid of those stock tires she handles completely different (for the better) and well with the belt can't help ya for i am still trying to get mine tight gonna order a red spring for mine soon along with a new belt

 

Mudbugs are 6 ply and only 1/2 lb heavier than the same size Mudlite.

 

So you need the tool to hold the secondary? How much is the Cat tool? I've only done the AC and Polaris clutching, so I don't have a Skidoo TRA clutch tool :-( (yet). Now if it were Cat SLED tools, I'd be covered!

Man that thing has some snot ! Can't wait to try the Dyna on it tonight !

 

By the way, thanks for the answers guys!

 

Go to ArcticChat.com,find the "VDI snorkle" thread,page three,scroll down to the pic of the left hand side of the 650 and look close,it has the up dated screw grommets.(its my bike by the way,and thats me riding it in the other pic)

The pics are in ATV mods and tech tips.

 

i myself fabricated my own clutch compression tool i can't remember where i found it i will try to look it up for you but it consisted of a lag bolt and i fashioned a piece of pipe hmmm i will try to find it for you

 

ok go to the kawasaki forum and look up a thread titled "spring compressor tool, black spring" and it was from january 5 2003 so it was froma while back but they give good advice on how to make your own and where to buy them