Hello All,
I got myself into a project and need some input from the experts on a few things.
My Dad gave me his old 1995 Big Boss 6X6 since he bought a new Sportsman 400. The machine has been through a lot in the last 10 years and needs some work. First off the tranny is shot, so I got one out of an Explorer 400. It just needed a new gasket so I cleaned it up pretty good. Now the big question is putting it back into the frame. Is there a trick to lining this up so the clutch is straight? It looks like I can adjust the mounting brackets but I'm not sure what I'm lining up. Do I just align the secondary with the primary on the front or back need some input here.
Also the exhaust is shot, so I will be replacing it, but why replace it with a 200.00 stock unit when I can get a about 8-10 HP with an after market, but do they make one to fit. The body is basically a trail boss with the 400CC 2-stroke. I tried to fit a HPD pipe I had from my Scrambler but this will not work at all unless I want 3rd degree burns on my right thigh. I want to use a stock Scrammy muffler though so if any one has one let me know.
I will also replace the piston since it is ten years old. This bike never even had a set of rings replaced. I don't know how the skirts didn't break of the piston. I know they are fairly weak. So the next question is should I put the big-bore piston in or don't you think it will be worth it, remember this is a 900lb machine so it could use any extra power I can get, but can't be to radical it is a pure utility.
I also will need two new CV boots for the front four new sprockets and chains for the two rear wheel drives and new handle bar controls for the light etc assembly and the throttle and 4X4 assembly. Anybody know of a good place to get these besides the stealer.
Thanks for the help. I will keep you updated on my progress as I go along.