I installed the digital tach that Blade carries. I like it, but wanted it mounted right next to my TrailTech spedo for ease of viewing both at once. I was starting to think about CVT mods and I wanted a way to measure my RPM changes.

I ran out of dash space, so I cutt me out a new instrumentation panel from some sheet metal I had. It allowed me to have be a better view of both the spedo and tach side by side. I hope it isn't too hard on the eyes?

Note: I did use rubber washers on that puppy so I wouldn't crack my dash plastic.

New Talon stock CVT data:
Idle with choke still on = 2,170rpm
Idle with choke off (warmed up) = 1,610rpm
Clutch just makes buggy just start to creep at 3,000rpm
Clutch fully engaged at 3,700rpm
Wide open 9,200rpm at 29.7mph.


Yes, I could see it OK, but I must admit that I do like it much better now! It's just neet having them right next to each other for ease of viewing. In my spedo's origional location, I found myself having to lean foward a bit to be able to read it. This was due to the downward curve of the dash. I no longer need to do that, and the numbers on the display are easier to read being located closer to my face.

I just received my two new custom made SandMan mirrors!! They are well made and will be a nice adition to my 2004 Talon that came mirrorless.

Just 1 shot before mounting.

Great job SandMan, You know your stuff!

SandMan (My new friend Tom), is a member of BuggyNews. A machinist by trade, he made the custom mounting brackets to fit the brush guard bars. He just baught me a good quality mirror set to work with, but hand machined the custom buggy mount's out of T-6 aluminum.

Very good work there.

THANKS ALL !! Hope you enjoy them Scott.

FYI - The mirrors are $120.00 for the set. I don't think that's a bad price considering the quality of the mirrors, and the T-6 hand machined aluminum mounts. It would be nice if T-6 aluminum just grew on trees, but that's not the case! Unfortunately, custom made quality parts are never cheep.

I might mention I did try the 3rd seat mod, but opted to take it back out. Steering behind your back was bad enouigh, but hitting the brake was really a bear!

My stock 2004 Talon battery died. It would no longer take, or keep a charge. I went to CarQuest looking for a replacement. The man took the number YTX12-BS off of the stock battery for his computer. CarQuest's replacement battery has the number ETX12 rated at 180 Cold Cranking Amps. The battery was $54.00 with a $5.00 credit from the old battery. I am not sure how this one will stand up next to the stock one. He did mention this one was a 'non-spillable' version.

Battery measurements:
Length: 5 7/8in.
Width: 3 7/16in.
Height: 5 1/8in.
12 Volt
10 Ah @ 10hr rate
180 CCA

Note: This battery will fit just fine in your stock battery box withought any mods.

Some text I found about the battery:

Description: Premium quality absorbed glass mat technology (AGM) is ideal for ATVs, motorcycles, personal watercraft (PWC) & snowmobiles. The Power Sports AGM Battery was designed for more than performance; it was designed for the enthusiast. Completely spillproof and leakproof; frequent replacement and high maintenance are over! The AGM technology increases power while improving rider and environmental safety. The key to this technology is the highly porous microfiber separators, which completely absorb and trap the electrolyte. Molded top and side connection terminals provide versatility, increased strength and durability. The Power Sports AGM Battery provides the most advanced power and value in the industry and are made in the U.S.A.

Chemistry: AGM
Volts: 12
Color: GRAY
Ah/Mah: 12
Replaces: YTX12-BS, YB12B-B2, WESTCO 12V12-B, YUASA YTX12-BS, INTERSTATE YTX12-BS, GS GTX12-BS

I thought the stock seatbelts were bad, due to them working loose every 5 minutes or so. I went to the Jeg's web page and liked the RCI 5-Way Harnesses in red with the individual cam lock. The red belts look better on my black seats, rather than the black on black I had. They will hold you in the buggy much better, especially small children who can slip through the bottom of a stock belt.

I had to put the torch to an old bowie knife I have, to heat it up before cutting my belts to the propper length for the buggy. The hot bowie knife cutt/melted right through the belt easy! I would also press the 'keeper' end of the belt, onto the side of the knife, to insure the entire 2" end would melt togeather a bit. I didn't want frizzys on the ends of the belt where I cutt.

You will need to drill a hole in the bottom of your buggy to mount the bottom strap, but it's no big deal....

The mounts for the sholder harnesses were lined up too close, and pointing directly at the back of my neck. I thought I might get hurt by them, so I wanted to mount them to another location.

My solution: I had to lower them, and I wanted them to be as strong as I could make them, as easily as I could.

It looked like to me getting the tubing involved for strength, was the way I wanted to go. I picked up the strongest pipe clamps I could find in the store, along with some monster washers. I put the clamps around the tubing, and bent it flat against the buggies metal plate. I drilled holes big enouigh for the bolts. I made sure to pinch some monster washers in there too, before cranking it all down hard. I dont know if it would pass a saftey inspection or not, but I feel like it should keep my head away from the wheel. The lap belt should hold me in too.

I feel better knowing I don't have 2 metal bars pointing directly at the back of my neck.

Looking back on this mod, the 2" belts were a bit of overkill. There are cheeper, thinner 5 point belts to be had, that work well. I still like my belts and all, but I wouldn't want you to think that two inch belts, must be the way to go. Blister baught these (Part number 54000-16-06 'In purple')and liked them allot.
http://search.store.yahoo.com/cgi-bin/n ... earch.html

These babies do really hold you in, and the turn the knobb, quick release is fun too. 4 belts will let go all at once. 'Click' ....

I did upgrade my stock clutch to the Koso HP clutch. It works, but I am not a big fan of the rather high engagement RPM of around 4,400 rpm.

Let me start by listing what I changed in the CVT.

1) Stock clutch with worn down pads to a new KOSO clutch.

2) Stock 1000rpm torque spring to a 1500rpm torque spring.

3) Stock Talon rollers around 13g's to MRP 10g'ers.

4) Stock Talon variator to KOSO variator.

5) Stock Talon Gates Powerlink VE 743 20 belt to the Comet 203581A belt.

Stock - Idle with choke still on = 2,170rpm ** After Upgrade - Same
Stock - Idle with choke off (warmed up) = 1,610rpm ** After Upgrade - Same
Stock - Clutch makes buggy just start to creep at 3,000rpm ** After Upgrade - 4,400
Stock - Clutch fully engaged hard by 3,500rpm ** After Upgrade - 4,650rpm
Stock - 5mph - 3,660rpm ** After Upgrade - 4,590rpm
Stock - 10mph - 4,650rpm ** After Upgrade - 5,480rpm
Stock - 15mph - 5,360rpm ** After Upgrade - 6,260rpm
Stock - 20mph - 6,530rpm ** After Upgrade - 7,020rpm
Stock - 25mph - 8,210rpm ** After Upgrade - 7,800rpm
Stock - 29.8mph - 9,280rpm ** After Upgrade - 8,290rpm at 30.3mph

My top speed broke the great 30mph barrier for the first time ever, but my top rpm dropped by 1,000. This must mean I am getting a taller gear ratio out of the KOSO variator and Comet belt combination? I don't know of any other good reason for me to now be able to hit 30.3MPH at 8,290rpm? I could not pull that off before the mod.

I also suspect the stronger spring, will lower your top rpm by some amount too. Between the 1500rpm spring, and the Comet/Koso taller gear ratio, I lost 1,000 off my top rpm. The stronger spring should also raise the clutches initial engagement rpm by some. The clutch shoes will have to work harder to spin up to make contact with the bell.

I do know the stronger spring helps to prevent unwanted clutch slipping, and excess heat from friction, so I still do like the spring mod. Heat makes all things fail quicker in your CVT.

I would say my buggy now, does not like to run at just 5mph. As soon as the clutch begins to make the buggy start to creep, if you just hold the rpm constant, the buggy will find 5mph+ quick.

For me, I want a clutch to engage and stay engaged below 4,400 rpm. The hunt for the ideal clutch goes on. The Koso clutch arms are lighter than our stockers, and the MRP.

Personal note: For me the 10g rollers moved my normal rpm operating range a bit too high for my 2004 geared buggy. It was reving too high, at slow speeds for my liking. I knew 11ish was going to be just about right for me.

Remember: The 2004 Talons and Twisters have lower gearing in the engines transmission, than the 2005 models. For 2005 they installed a GY6 transmission gear that had a 4 extra tooth count, for added top speed. A good running 2004 Talon is geared down to a max top speed of 30mph -vs- 40mph in the 2005 Talon.

The stock 2004 Talon with it's 16 tooth drive gear, and 39 tooth axle gear, means that the drive gear get's the privilege of turning a whopping 2.44 times, before expecting the alxe gear to complete one revolution. This equates to a stronger bottom end! The taller geared buggies with 16 tooth drive and 31 tooth axle gears, will allow you to hit a top speed of 40+ MPH. This however, does come at a price. They must task their driver gear to do more work in a shorter amount of time. The taller geared buggies require that for the axle gear to complete one full revolution, the driver gear will only get to complete 1.94 revolutions. Your 2004 Talon's drive gear get's to enjoy turning exactly 1/2 of a revolution more, before having to accomplish the same amount of work.

The new transmissioned geared buggies with the 4 extra teeth are handling this extra work there, but it is still extra work that the 2004 Talon does not have to do, in the same amount of time. You will feel the difference with more low end power.

One quick shot of the Comet 203581A belt. It is bigger, and I was hoping it might climb a bit higher on the variator, giving me a higher top gear ratio. I ordered it from the link below and received great service. I don't think I am experiencing any belt slippage using the Comet belt in my Talon. I therefore consider this belt to be a readily available, reasonably priced alternative to ordering the official Carter replacement belt. The fact I have the 1,500 RPM rated clutch spring installed, and used Prestone belt dressing, might be factors in why the Comet belt seems to work well for me? I will say the Comet belt is made of quality material as standard belts go, which is the type I prefer to run in my buggy. I have heard Kevlar can cutt into your variator, and when it does let go it usually is all at once. With a standard belt it usually begins to shread slowly, and with some luck you might be able to limp back to camp with the CVT still working. I have yet to break a belt, and my stock 2004 Gates Powerlink VE 743 20 belt still looks new too.

Comet belt- http://www.mfgsupply.com/m/c/203581A..html

Before installing my Comet belt, I used Prestone Belt Dressing on it. I hung the belt on a string, and gave it multiple thin coats with the easy to use spray can. Some guy's don't like belt dressing in general, due to it attracting dirt. This might be true but it does seem to make your belt nice and grippy. I think my CVT cover and foam filter will keep most of the dirt away from the belt. I have no doubt that the belt will hook up at least as good as it was withought the dressing. I wanted to give it a try, also keeping in mind that I was going up in belt size some too. So far, so good.

Prestone's view: Prestone® Belt Dressing conditions V-belts and fan belts to prolong belt life. Age and temperature can cause belts to wear out prematurely. This formula conditions belts to help prevent premature wear. Prestone Belt Dressing also promotes better grip and traction. It helps eliminate squeaks and chattering, and reduces the strain on bushings and bearings.

I upgraded to the Koso HP variator. I liked the Koso variator, and think it may have added some top speed to my buggy. The day I put the Comet belt in, with the Koso variator, was the first time I broke the great 30 MPH barrier in my Mountain Goat geared Talon. 30.3 MPH to be exact, and is still my current high speed record. I baught the Koso variator from that 'Stu' guy at Blade (Link provided below), and receied great service.

Blade link- http://www.bladepowersports.com/product ... at=28&pg=3
Note: Now it looks like they are selling another HP variator, Teflon Coated too. Look's to be a good one? (The Prodigy variator)