Hi All,

I'll be upgrading my stock 1990 TrailBoss 250 in stages, 1st with a DG pipe, then later with a shaved head, colder plug, and ported cylinder, and finally with a larger carb and (perhaps) a shaved flywheel.

Could the experts recommend clutch mods for each of these stages of tune?

Regards,

Jim Wooten

 

Dont waist your cash on a DG pipe for that old of a bike.Find a Aaen or RcR and get the matching clutch kits for the pipe.
Best bet would be to get a fresh topend,K&N filter and a Polaris white primary spring and ride it.

 

or maybe even contact rcr racing(rick ritter) for his input on the best bang for your buck. i beleave like he said get matching componets so they will enhance and not hinder each other.

 

Guess I should have mentioned that the bike has been very lightly used (still has the original tires in really good shape) and was always stored in a heated garage. I should also mention that the DG pipe is a done deal already (It was <$100 and hard to pass up).

I've gone through it from stem to stern and found a) 1 loose chain in the 4wd; and b) 1 zerk fitting that needed to be changed. As for modding a bike this old, why the heck not?! Parts are relatively cheap, the motor has been around forever and has proven potential, and there are plenty of folks who understand how to make it bark. Not to mention the fact that it's far simpler to work on that it's 300 and 400 water cooled cousins and has less parts to go boom that any of the 4 strokes. I can't think of a better bike to hot rod!

And saving the best for last, you can find these bikes laying around occasionally for $800.

Jim

 

If you insist on modding this one ditch the DG pipe(try to get you $$$ back REALLY it makes no power just noise on the 250s)Find a 1987 Cyclone exhaust,Cylinder(you can port the 250s easy) Then use the stock Cyclone clutching.You will get great results.
I have an old 93 250 Trailboss and it is a fun machine stock and doesnt make much noise.Now my 500 is a dif story

 

I'm a fan of the 250, with that said, I would buy a 400 sportsman instead. Stock HP the same as a modded 250, and alot more options after that. You can find those reasonably priced also. By the way my 250 sticks right with stock 400 polarises and is alot of fun. Doc

 

Hmmmm, I take your points, guys. The DG is going back (especially since I just found out it isn't USFS approved - how stupid it that!?)

A Cyclone clone is a great idea as is the 400 sportsman (although they are kind of rare around here, it seems).

How do you recognize a Cyclone pipe? And what is the stock clutching for the Cyclone?

Jim

 

Found a drawing on bikebandit.com. The Cyclone pipe looks pretty unique - it has a can on the end with the exhaust pointed straight down.

Only made for one year as well. Anybody here got one? None on Ebay right now....

Will it mate to the Trailboss header pipe or should I get the Cyclone header as well?

Dang, I am just full of questions this morning...

Regards,

Jim

 

Be patent and all of it will come up on Ebay.I will post you the clutching specs when I get out in the garage this weekend.Drop me a PM