Getting ready to install a 136" Expert-X any tips???

[tonykof]

Getting ready to install a used 136" Expert X in my 05 Warrior this weekend. Anyone have any tips??
Thanks Tony

 

[grader]

measure twice, drill once.

 

[LazyBastard]

Good advise.

More advise:
The tunnel bracket they supply with it will not fit. I remember a suggestion somewhere (might have been with the install manual) that suggested cutting off a huge chunk of the bracket. Rather than that, just trim off what you NEED to. Hold the bracket up on the inside of the tunnel and draw a line on it to figure where you need to cut. You can use a regular wood saw, like a table saw, miter saw, radial arm saw, etc., to cut aluminum since it is a soft metal. It won't hurt the carbide tips. But cut slowly, otherwise it'll make a mess.

 

[tonykof]

Thanks for the tip, I'll lay it all out tomorrow & see about the brackets. Are you talking about the ones that go inside of the tunnel or the outside ones?
Thanks tk

 

[grader]

go to the totalyamaha site under product reviews there is step by step install pics and instructions. on my 03 i used the large outer plates but when i put it into my 05 i installed 1/16 inch aluminum plates inside the tunnel. looks cleaner.just double check all measurements before drilling anything.

 

[tonykof]

LB - quote: "The tunnel bracket they supply with it will not fit."
Are you talking about the Aluminum plates on the outside or the stainless steel plates that were supplied in the kit for the inside?

grader - quote: "on my 03 i used the large outer plates but when i put it into my 05 i installed 1/16 inch aluminum plates inside the tunnel."
I'm confused on how this would work. In the installation kit I was supplied with stainless steel plates for the inside of the tunnel.

Okay, question for anyone who has installed an Expert X in either a warrior or RX1 (I'm pretty sure it's the same)
In the installation guide is says. quote:"NOTE: For RX-1 customers, please go directly to pages 11 and 12 to bypass the general installation instructions."
Going by the pages 11 & 12 I am under the impression that if I put the inside stainless mounting plates in as they show I would skip the measuring from the ctr of driveshaft ect... Obviously I would check to make sure the outside plate holes would line up with the inside plates by holding it up to the assumed holes in the inside stainless plates..

Am I missing anything here??
Could someone that has done a somewhat recent install pm me they're ph # so I could talk to them about this?? I just don't want to end up with any extra holes!

Thanks Tony
218-783-6541

Ps. other info on my install - I'm currently running extrovets, studded track & CPR Turbo.

 

[grader]

pm'd you. the 05 tunnel is the same, but the location of the 4 inner plates might not line up exactly as the 03, because the running board coolers have a different shape inside the tunnel because of the mono skid. you will have to measure the distances back and down, and locate the small inner plates to fit flush with the inside of the tunnel. if you need to the plates can be cut to fit.

 

[jimmie d]

Do it with plates on inside and get a look like this.

 

[LazyBastard]

LB - quote: "The tunnel bracket they supply with it will not fit."
Are you talking about the Aluminum plates on the outside or the stainless steel plates that were supplied in the kit for the inside?

The inside plates are designed specifically for your sled and will fit very precisely. In fact they'll fit SO well that the only reason you need to measure anything is just to *make sure*. The outer brackets are the same for all sleds, and if you notice, the sides of the tunnels are deeper on most other sleds, hence they don't quite fit right on RX and need to be modified.

 

[grader]

the tunnels are the same, but, the flanges of the running board coolers are different on the 05 because of the brackets for the mono skid. therefore the 4 small inside plates will not line up exactly as they did in the 03. so unless boivin made a mount kit specifically for the 05 rx, the plates will need some minor mods and measuring to work.

 

[LazyBastard]

His is a warrior, it doesn't have a mono.

 

[grader]

right you are, then it should all fit without modification.

 

[bjowett]

Nope, they won't fit unless Boivin has changed the kit. The rear inner brackets did not fit my 05 Rage 136" with Proaction due to the cooler mount flange... they need to be trimmed quite a bit... hope this info is in time for your install.

 

[tonykof]

Nope, they won't fit unless Boivin has changed the kit. The rear inner brackets did not fit my 05 Rage 136" with Proaction due to the cooler mount flange... they need to be trimmed quite a bit... hope this info is in time for your install.

Your right brian. The rear brackets won't fit.. I have the front holes drilled & the rear holes marked in what I feel seems to be the correct location (bracket placement & measuring from driveshaft & top of tunnel to make sure) I'm not sure if I'm going to trim the rear bracket or trim down the cooler mount flange some..

conclusion.. on an 05 Warrior the basic tunnel is the same however the cooler mounting flange is different where the rear bracket normally mounts.

I've now seen more than a few guys that are not putting the ugly outside aluminium tunnel brace on. Will the tunnel hold up with just the inside stainless steel brackets? My sled doesn't really get pounded much, seems I spend most of my time on the trail, lake and/or drag racing. The only reason I'm changing suspension is to stop the track from ratcheting so bad (ext drivers arn't getting it done...)

Thanks for your help
Tony

 

[LazyBastard]

Nope, they won't fit unless Boivin has changed the kit. The rear inner brackets did not fit my 05 Rage 136" with Proaction due to the cooler mount flange... they need to be trimmed quite a bit... hope this info is in time for your install.

Your right brian. The rear brackets won't fit.. I have the front holes drilled & the rear holes marked in what I feel seems to be the correct location (bracket placement & measuring from driveshaft & top of tunnel to make sure) I'm not sure if I'm going to trim the rear bracket or trim down the cooler mount flange some..

conclusion.. on an 05 Warrior the basic tunnel is the same however the cooler mounting flange is different where the rear bracket normally mounts.

I've now seen more than a few guys that are not putting the ugly outside aluminium tunnel brace on. Will the tunnel hold up with just the inside stainless steel brackets? My sled doesn't really get pounded much, seems I spend most of my time on the trail, lake and/or drag racing. The only reason I'm changing suspension is to stop the track from ratcheting so bad (ext drivers arn't getting it done...)

Thanks for your help
Tony

You need that outside bracket, and it will look better with it installed than without -- it covers up all the ugly holes left from the previous suspension(s).