Proaction Expert X Install

Totallyamaha Pro-action Expert X Install

Before beginning the installation, Totallyamaha recommends that you thoroughly read the installation package provided with your Expert X, Be sure you understand the mathematics and all of the layout procedures described. Take your time with the layout, it is very critical that your new suspension be mounted parallel to the tunnel and perpendicular to the drive shaft. (If any of the information provided below conflicts with the installation package provided by AD Boivin, use the their information ) Look through the parts that are provided and make sure you are not missing any mounting hardware. (Click to see pic)

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Step one is to remove your pro-action skid frame. Slightly elevate the rear of the sled so the track is about 2" off the ground. Using a 17 mm and 19 mm wrench loosen the rear shaft slightly. Take a 14 mm socket and ratchet and release the track tension. Be sure to count the turns equally off the rear adjusters. (This will aid you in slipping the stock suspension back through the track.) Next remove the (6) 14mm bolts from the tunnel and drop the skid to the floor. At this point it would be helpful to remove your seat. Unsnap the front, remove the banding flap to the gas tank, flip open the trunk space and remove the (2) 12 mm nuts. Lift the seat slightly to reveal the tail light wire, unplug and remove seat.

With the charts provided (Fig 2) determine your drive cog diameter and the number of drive teeth. Our drive cog Diameter was approximately 7 1/8" with a 9 tooth pitch. Our "A" Dimension was 10 1/4" (Center of drive to 1st hole), our "H" Dimension is 5 11/16" and our "B" Dimension calculated to less than 5 3/8". As noted in the installation guide we used 5 3/8" min from the inside of the tunnel down to the 1st hole. Once the "B" Dimension was calculated the "C" Dimension of 4 3/4" was determined from the chart.

Using Fig 3 of your installation guide, you will need to calculate the dimension from the collar on the drive shaft to the 1st hole "L" ( We took our "A" Dimension of 10 1/4" minus 1/ 2 of the 1 5/8" Diameter Collar to get "L" Dimension of 9 7/16"). We then cut a flat bar to the "L" dimension to use as an aid in scribing center of the 1st hole. See pics to the right for more explanation.

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With all of your dimensions and the tools shown above, layout your 1st hole location on each side of the tunnel. To verify that our layout was the same on both sides and to ensure the mounting holes were parallel to the drive shaft, we measured back from the edge of the stock middle-mounting hole to the center of each of our layout marks. Our measurement was 5 13/16" on each side confirming out layout was parallel

Although we later found that it was not necessary we also removed the stock suspension’s middle mount plate on each side as shown above. This mount will not interfere with the new suspension and can be left in place.

Carefully place the Expert X side plates against the tunnel in their respective places using the previously drilled holes. Remove any rivets that will prevent the main mounting plates from sitting flat on the outside of the tunnel surface. See the picture to the right for the seven arrows indicating the rivets we drilled out.

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From the inside of the tunnel, center punch and drill the front most holes using a 25/64 drill. Using the bolts supplied, temporarily mount the side plates through the front hole and rotate the rear of the plate until flush with the top of the tunnel. This will achieve the 4 3/4" dimension to rear hole. Scribe the rear hole, center punch and drill using a 25/64 drill.

Temporarily bolt the side plates to tunnel using the holes just drilled. Locate and mark the rivet holes along the top edge of the side plates. Layout two holes approximately 3/4" down and 3/4"- 1" from each edge, space two or more holes evenly between the ends. Remember to leave room to remount your seat snaps. Pop Rivet the plates to the tunnel. Use at least 4 rivets. Remove your temporary bolts and position your inner reinforcing backer plates as shown (Right). Align the backer plates so that at least 2 rivets on each plate will fasten through the backer, tunnel and outside main plates. Using your temporary bolts to hold backing plates and side plates in place, drill through all materials and pop rivet. See pic for detail. Make sure at least 8 rivets are used in each side

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Once your side mounting plates and reinforcing backers are riveted and secured properly you are now ready to install the Expert X. “The softness adjuster (18mm nut) should not be installed on the shaft that connects to the softness bar (Big Black Plastic Link Bar) prior to mounting the skid.” Next take the Expert X skid and slip it into the track and slide to its approximate mounting position.

Take the supplied hardware shown in the upper left image, Slip the inner nut bushing and outer spacer bushing on to the front (upper) swing arm on both sides. Lift the front swing arm up and align with your new front mounting holes. Holding the back side of the inner nut bushing, slide the front bolts through and hand tighten both sides.

Slide the alum spacers over the rear upper mount/idler shaft on both sides and swing the idler shaft into place and align with the new rear holes. Slide the rear bolts through and hand tighten both sides. Torque all four bolts to 38 ft lbs.

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Install the 18 MM softness nut so it is flush to the end of the threaded shaft (Fig. 9). You may have to lift the suspension or lower sled to floor to get the nut started. Align track and set track tension by adjusting the rear axle bolts (18mm). Be sure to loosen the rear wheel bolts prior to adjusting and re-tighten when complete. Proper track tension should be approximately 1 1/2" gap at 15 lbs. See installation package (Fig. 10). Reinstall seat, don’t forget to plug in the rear light.

Follow the “Adjustment” recommendations included in the installation package, adjust the Expert X to your weight and riding style and You’re ready to " Hit the Moguls".

Special Note: If you have done the install correctly you will have at least 3/8" gap when the track is under tension from upper arm plastic protector to the track. (Fig. 8)

Pictures to the right are some of the tools that will be needed to install the Expert X.

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Using the tools shown in the pic to the left, will be required to set up your Expert X to the riding style and weight you prefer. See manual or additional info below.

Note: Make sure you set your overload springs to the brass bushed holes in the swing arm. Most likely they will be shipped and set in the top slot hole above the brass bushing. See Pics to the left.

Also be sure to Red loctite (#272) all mounting fasteners once you are happy with your installation..and Torque to 400 in-lbs.

Below you will find additional information to help you adjust your Expert X. This is taken from the installation guide.

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Below you will find additional information to help you with your Expert X hole layout. This is also taken from the installation guide.

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Totallyamaha is not responsible for any damages that these modifications may cause to your vehicle; any modifications are your responsibility if you choose to do so. We are providing information ONLY. Some of these modifications may VOID your warranty and that is your responsibility to look into. The Totallyamaha users have passed along most of the information found on this site. If you have any questions or concerns about anything on this site talk to your dealer before using any of the information. Totallyamaha will not be liable for any damages or personal injury from any modification performed from this site.

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