I just bought a /95 300 2x4 and I want to remove the clutch cover to check things out and possibly play with the clutching a bit.The bike looks the same as a trail boss but it has the 300 instead of the 250. My problem is that the bolts wont come out of the cover. The nuts are turning in the plastic backing plate.I don't think the cover has ever been taken off this bike since it was new!!Any ideas how to get this off without cutting the heads off the bolts? Anyone also have any suggestions for playing with the clutching a bit. How many Lbs. of tension should be on the secondary?

 

Try prying out on the outer cover you my mess it up but you will have to get it off sooner or latter.As for the clutch my experiance is put a white spring in the drive clutch and go from there with the secondary.On my 400 2stroke Sportsman i run a green Aaenn drive and a blue Aaen secondary in holes 2 and 2on the helex.It is very quick and slows down good on hills.On my 425 i run a Polaris white spring with thee stock spring and setting on the secondary.Its not as quick but shifts better in the woods.Just my $.02 worth. -------------------Brad

 

Well I got the cover off by drilling the heads off the screws.4 out of 7 screws had to be drilled.The 2 bikes you're talking about have a lot more horsepower than a 300 air cooled engine. I need to know from someone with a smaller engine what settings I should try.Also does anyone know how much belt deflection thee bikes should have?And also what is the stock width of the belt?

 

I have a 96 300 Xpress. I have ported and polished my engine. From my experience I can say that the white spring in the primary does help it. I personally am running the green spring with 51.5 gram weights(stock is 48 gram). I will probably end up with 55 gram weights before long. I want it to shift a little bit harder. I have the yellow spring for back-up in case the 55 gram weights are a little to heavy. As for the secondary, I would say, leave it at its stock 2/2 setting. I've tried each setting when my engine was stock and this was the best setting. I will probably go with a softer setting the next time I have my cover off.

My final advice, install the white spring. Trust me, you'll like the harder acceleration this will give you. Its not a huge difference but it is a noticable one.

A brand new Polaris belt measures 1.188" wide. Polaris states you should replace it at 1.125". I usually never let mine get down quite this far. Mine seems to get a little better performance with a new belt. Thats probably why I change it so often.