Well, after getting over the three factors I have not had in a while: Time, money and motivation... I have began tearing into the 2001 DS motor I purchased used. I have the top end off, clutch, stator, etc off and debating whether or not to split the case. Experienced guys, should I? What should I be looking for to replace? Any aftermarket stuff that can make it better? Bear in mind, this is a motor I really want to build up, I just have never tore a DS motor apart. Any hints or anything would be appreciated.

 

http://www.ljsoftware.com/DS/DS650Main.html
here is a site that you might want to help its pretty useful

 

here are 2 also useful sites

http://www.ds650.flatlandersatv.com/

http://epc.brp.com/login.aspx?Return...ookieSupport=1

 

I just did it myself about a month ago.

I was not really that hard. Make sure you download Hightower instructions and follow them closely. If you plan on
keeping the motor i would split the cases and replace the shift forks. If you plan on building the motor, it is a good time
to get the gears race cut. I had HPR do mine and the tranny now shifts like butter. Most of my ridding is trail ridding but
I still suggest it.

Just take your time when taking it apart - follow the instructions, make each part in sandwich bags and you will do fine.
Also make sure to invest in a good torque wrench (SNAP - ON).

Drop me a line back if you have any other questions ???


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What is the cost of getting the gears race cut? I don't see a price on their website. Also, does it affect the durability of the transmission?

 

I believe it was $500.00 to have the gears race cut. Having the gears cut will help the durability of the transmission
because it goes into every gear with ease. You won't have to hammer down on the shifter.

 

the link at my site takes you to the same site bombrider posted, they are not my instuctions bit rather just linked from my site to wshrdskin's site.


the "race cut" refers to a process known as "backcutting", it bevels the dogs on the tranny gears such that they lock together more positively preventing them from slipping out of mesh under hard load. this does not sacrifice durability, but rather enhances it.
there is also the process of treating the shifting forks to add durability, chryogenics used to harden them.
these two processes are common in serious hp DS motors that are big bored and stroked, THEBOM can hook you up with these services, as well as HPR, or the Preacher, you are closest to the Preacher. He can also lighten your flywheel for shedding a bit of internal rotating weight.

 

like as posted, do the backcutting, and cyro treating you will be glad you did. there are a few other things you can do like oil guiding plate, supposed to add 1 HP.