Need Some Polaris Scrambler Help

[BigGreenMachine]

Got a buddy with a 2x4 Scrammy 400. He is in the middle of installing a new AAEN pipe and clutch kit but has hit a snag.

The middle bolt on the clutch won't budge. He is trying to install new springs and the center bolt won't budge. Anyone know if the bolt is opposite thread or Loc-tited in? Any help would be appreciated.

James

[BigGreenMachine]

That worked great for me. Forwarded it on to my budd and hopefully he can use that as a reference. Waiting for the 400 Scrammy expert to get back to me with answers too.

Thanks Jes!

[TravEX]

My friend did that to my Scrambler after he bought it from me. I could not believe how strong that thing was after the pipe and clutch spring. BIG DIFFERENCE!!!!

[Wickedfinger]

Which clutch is he having trouble with - the Primary or the Secondary?.

[85hondaatc125m]

your having trouble taking the primary clutch are ya?I just had to take the primary clutch off of my Cyclone, it says you need a special Polaris tool, i know a way you can get it off will tool around the garadge, if you wanna know how just say so. Unless you already got it off,

[conig]

the aaen pipe does make some power, if he hasn;t replaced the piston with a wiseco he needs to with the increased rpm of the pipe he's setting himself up for a time bomb.

[BigGreenMachine]

Believe its the secondary.

[Big D]

your having trouble taking the primary clutch are ya?I just had to take the primary clutch off of my Cyclone, it says you need a special Polaris tool, i know a way you can get it off will tool around the garadge, if you wanna know how just say so. Unless you already got it off,
If he dosen't (I do) Can't get the one on my 250 off. Didn't mean to jump on his thread

[conig]

get a piece of 3/4inch fine thread all thread from the local hardware store and two nuts to fit. jam the two nuts together or weld them on at one end.

insert a 3inch 3/8 socket extension into the hole for the primary clutch and then tighten down the all thread. the socket extension will push in the crank and seperate the primary clutch from its taper.

you can also use a 3/4inch fine thread trailer ball.

[conig]

you shoudn;t have to pull the clutch to replace the spring just get the center one loose and remove the 6 outer bolts.

[85hondaatc125m]

get a piece of 3/4inch fine thread all thread from the local hardware store and two nuts to fit. jam the two nuts together or weld them on at one end.

insert a 3inch 3/8 socket extension into the hole for the primary clutch and then tighten down the all thread. the socket extension will push in the crank and seperate the primary clutch from its taper.

you can also use a 3/4inch fine thread trailer ball.
I did the same just didnt use the nuts, put the 3 inch extention in the clutch 1st, get a fair size bolt, maybe 4-5 inches of thread that will fit in the clutch(like he said i think it is 3/4inch fine thread) start tightening with hand until you cant anymore, then get a wrench to fit the bolt and tighten it, and the clutch will just pop loose. Yea, i guess im 1 hour too late to reply to that, ill mention it know because I made this mistake, the part of the extension that connects to rachet, it goes in first, by the way. If you need anymore help just let me know, oh and conig, sounds like he knows his stuff too;)

[85hondaatc125m]

Believe its the secondary.
The secondary clutch should just pull right off, maybe spray it with some WD-40

[Big D]

Great, thanks guys I will try that tonight,

[BigGreenMachine]

He got it installed today, just a case of a stuborn bolt. All thats left to do is rejet. Anyone got base line jetting specs for this new pipe?

[Wickedfinger]

Is it the Trail pipe or the Top end?. What carb, stock 34mm?. If its the 34mm - stock main is #230. For the Top-end pipe, most guys end up with a 250/260 main - but - that depends on your altitude and temperature. With my 38mmTMX and the Top Ender, I run a 280 summer and a 290 winter.

[conig]

I landed on a 250 but I have high humidity and heat down here in florida, in the winter I alsways have to go up to a 260.

[BigGreenMachine]

Top end pipe, the 10hp AAEN pipe. So I'm hearing 250/260 main for stock carb. Thanks fellas.