Welcome to the forums! Yes I remember the shop ordered the DJ Kit for the 300, same with the Muzzy pipe. I'm running the 132 and 40 jets with no lid, absolutely flawless for over 12,000 miles now. 13 tooth was also a nice addition, and in fact was actually the first mod I did. then when I had the shop do the jetting I had them throw on a 45 tooth rear sprocket. The only mod I want to do now is the kick starter.

 

Thanks guys, but I'm still struggling with that damn nut! I put some penetrating oil on it and am going to give it another try tomorrow. I tried an impact gun I have with the rear brake pressed hard, but it still won't spin the nut. Correct me if I'm wrong, but it seems like it should come off counterclockwise like any other nut. And do I have to do anything special with that washer with the one side bent up behind the nut, or should that thing spin right off with the nut?

 

Hey Man, Welcome! Flatten that washer that you're speaking of. A new one is flat, you bend it up after install for a safety thing. Cool on the new bike. They are pretty kick a$$. Good Luck The nut is a reg type--not reverse. That washer doesn't need to be totally flat, just the bent part you noticed. Later!

 

Whew - I finally showed that nut who's the boss! Flattened out the washer and left some penetrating oil on for a few hours. Finally had a friend of mine who's a little on the heavier side sit on the bike, nose it up to the wall of the garage, and hold the rear brake while I cranked with a ratchet and a 2 foot section of pipe to break the nut free. Good lord, was that thing on there! The chain tensioners were previously on 4.5, now on 6 to get the correct amount of chain play with the new sprocket. Got dark on me so I'll have to take the bike for a spin tomorrow and follow with a report.

One annoying thing - with the chain tensioners set at 6, the tensioner on the left interferes with a bolt attaching the chain guard to the frame. Anyone else encounter this problem? Seems like an engineering flaw that I can't find any way around. I had to keep the bolt out for now.

Another thing - the new front sprocket does not have the rubber bushings on either side that the old one has, presumably to keep the grime away from the shaft. Guess that's how the replacements are? Ordered it from Rockymountainatv.com.

 

So you didn't have the washer bent out flat before? Uhhh that was the problem. Glad you figured it out.