i think im gonna put a green spring in the trailboss. would i be able to install it myself, or would i have to take it to my crummy dealor? can i get a Cylmer manual for the trailboss??

 

It's very easy,take the middle bolt out of the primary,then remove the six smaller bolts around the face ,the plate will come off and the spring is right there.Hope this helps.Later.

 

Get a phillips screwdriver and take out the 4 screws holding the floorboard to the frame.
Take off the seat.
Pop out the top plastic body panel.
Remove the clutch cover snorkle with I think (2) 7/16" bolts.
Remove the hose clamp that attaches the snorkle to the clutch cover.
Go around the clutch cover with a 3/8" and remove all of the screws.
Pull the floorboard away a bit and work the clutch cover on out, over the clutches.
Remove the (6) 3/8" bolts holding on the outer clutch plate. They are in pairs and I suggest taking them off, putting them on like you do a car time, loosening/tightening every other one.
Remove the 5/8" Bolt down the center of the outer clutch plate. You may need to slip a large screwdriver through the center of the clutch to hold it in place while you loosen all of the bolts.

Pop off the plate and remove the blue spring.
Pop in the new spring and start to draw the outer plate on with the 5/8" bolt.
Tighten the 6 bolts hand tight, in sequence, every other one.
Draw the center bolt all the way in. The one on my 325 was only torqued to about 35 ft lbs. The one on my 500 is the same part, torqued way up there to 50 ft lbs or so. Be careful and don't overtorque! I used a tad of blue locktite and torqued to about 38 ft lbs. That's pretty good for a bolt this size, but I'm also not a mechanical engineer.
The 6 outer bolts should be torqued to about 23 or so. Maybe we should call the dealer to make sure, but That's pretty close.

Put the cover and other parts back in place and you're done.

It's and easy job and I had no instructions. If you can change the plugs in your car, you can do this.


(Posted by Barley Legal from Atv time)

 

If I were you I would try a white Polaris spring or red EPI .I have a green Aaen in my 400 2stroke Sportsman and it works fine but it is moded out a bit.The white spring is not as wild on the engagement and you wont loose topend any at all.I run the white in my 425 and it is great.I put the green in it and didnt like it.

 

thanks bowhunterr2001. You said that If I could change the plugs in my car, I could install the spring... Well, im only 14, i dont have a car, but yes, i can change plugs pretty easy, so i guess i can do the spring. thanks[img]i/expressions/face-icon-small-smile.gif[/img]

 

Don't be surprised if you loose a little top end. If all you want to do is install a spring, I would recommend the Polaris white.

One more thing I'd like to add to what Bowhunterr posted, is to make sure you put the clutch back together so that it is aligned. On all the major components of the primary clutch, their is a "X" marked on them. All these "X"'s must be lined up. This is how the clutch is put together when it gets balanced. If the "X"'s aren't aligned, it may put it way out of balance.

 

I recommend using a wood handle or the such to hold the clutch while loosening or tightening.A metal end of a screwdriver might mark the clutch and put a stress spot on it. Also, the outer 6 cover bolts only torque to 90 inch/lbs.Bubba

 

I don't think you will be happy with the Aaen green. I had it in my Trailboss and I lost alot of top end, so I went to the Polaris white. I havent really gotten it out much since, but I can tell you that it's not nearly as aggressive. Still has a higher engegement (I can still wheelie) but I can go in reverse without the override. The Polaris white is the stock spring in most Scramblers and Sports, so you shouldn't lose top end. Be careful with the six 3/8" bolts on the clutch cover. I broke one putting in the white spring with a 3/8" drive ratchet. It came out easily, and I just made a trip to the hardware store, but still, you don't want to break any bolts.

 

Uh oh, I finally chose Aaen for my speed kit after speaking with Olaf. I was a little leary of his proposal for my '99 Xplorer 400 4x4. Should I change my order? Olaf suggested the following for my high altitude mix of road and trail riding:

Top End Pipe - He recommended I not do the "Torquer Pipe" since the Top End Pipe gives good performance throughout the range (bottom to top)

Spark Arrestor Silencer - no question here

Custom weights for my altitude (we chose 8000 feet to target middle)

Aaen Green Primary Spring - instead of red (this spring is much stiffer than a Polaris white I noted)

Aaen Blue secondary spring - he says I can use this even with the stock Primary spring.

No new helix - not part of recommended clutch kit?

 

You do not necessarily need a split helix. The custom weights with the stiffer spring are going to be used because you are at such a high altitude ans it keeps the rpms up. I am surprised that he didnt mention the fact of bumping the compression. I would take.020 or .030 off the head to help out as well. You need as much help as you can get when the air is that thin. Bubba