Okay guys I`ve purchased all the gear I need to change my ZR500 (carb) to a 600. I`m not sure if I want to make the change now, my 500 goes pretty good but when you ride with 600,700 and 800`s, its hard to keep up. Maybe I should just find a clutch kit that works really well and add a single or twin pipes, maybe change gearing. What do you think? I`ve tried several different clutch setups( BM and home setups) but am still open to suggestions. My gas milege isn`t very good now(about 85 to 90 miles per tank) and I was told it probably wont get any better with the 600. I was also told that the 600 could be made into a rocket ship with the right tuning and clutching. I guess I want to know if there is any big difference between the 500 and 600(besides 10 HP increase). Would appreciate any help to make the 600 into that rocket ship, I read about.

Thanks

Are you also adding PV because I don't think you will see much difference without them.

I stuck a 99 600 motor in my 98 zr500 chassis a couple years ago and there was a definate difference in power. Milage did go down but ive heard the 600 never got real great milage. It was a pain in the ass finding all the stuff but worth it. I needed;different pipe, cdi, airbox, carbs, clutch parts and thats it.

Good luck
Jeff

not to get you off topic, but where did you get your windsheild from? it looks good

I never had any problem with the 600's untill they add PV's little more top end but still beat them in 660,never really tried one top end though, wouldn't hardly be worth the trouble unless you were putting in the PV motor. IMO

You know what they say Camarro, "There's no replacement for displacement"!

Oxygen,
The windshield was purchased from Design Plastics in Omaha Nebraska (402)572-7177. This is the second windshield I have purchased from them, the first on was a see thru chrome with light green trim. I`ve had no problem dealing with them.

Thanks for all the input guys, so do you have any setups you want to share for the 500 or 600? Exactly what you said ZRJEFF, I would think there must be quite a difference in the power between the 500 and 600. I guess I wont know unless i try. Can always take it off, but would like to get it right the first time. Keep the comments coming and any suggestions greatly appreciated.

Thanks :div20:

Readytorace,
not putting in the PV motor. Sounds like you may have tried many setups,and sounds like you may have found ones that work. Willing to share!!!! :cn:

From my experiences a well set up 500 will always trounce the 600. Sell the 600 off and work on the 500's set up.

:div20:

My thoughts exactly.
ZR500 = Overacheiver.
ZR600 = Underacheiver.

:div20: displacement looks bad getting beat by a smaller sled ,but FUN!!! :beerchug:

all I can say is the little 500 has lots of potental, I spend many hours testing different stuff, Sorry but I don't like to share what I have learned over the years. :beerchug:

If you want to spend a little more $, try the D&D single pipe and clutching with the 600 top end and gear it up to the 2001-2003 ZR600 specs. Don't remember exactly what gearing that is, but you can look it up at alpha-sports.com. This setup runs pretty good, right with the older 700's and some of the newer valved 600's (XC6 for example). I think you'll like it. I believe that mouse_trap has a D&D pipe he could sell you - might want to send him a PM. I never got less than 11mpg using this setup even when riding hard.

Okay guys any suggestions for the 500? Where should I start? Should I put a single pipe,Twin pipes,reeds and then match the clutching to that setup ? Someone must be willing to share some info, if you don`t want to post it on here just e-mail me at camarrow_69@hotmail.com, and i will keep the info confidential and not reveal the setup.


MikeZR600,
Thanks for that info, I may try this if I don`t get any suggestions for the 500. I will contact mouse_trap and see how much he wants for it. I just spent quite a bit of money gathering together the parts for the 600 and not sure if I can afford to spend much this year.
Thanks :div20:

we will remember that....true hardcore sledder! :frech32:

clutch and exhaust your zr500

If you want to give away all your info and have it come back to bite you in the ass , go right ahead, Don't win races that way.

No, but you can offer some things to try....not just say, fuck you.....im not helping....dont have to give your excact setup, but some things to try, some advice would be great esp if your running the same sled.

I have given guys help on setups before, What works for me may not work for someone else, I will give a push in the right direction, but unless your right there to see whats giong on, it's better if they do most of the work themselves, thats what I was doing when I said to stick with the 500 instead of the 600. :cn: I will help anyone, anyway I can but learning is half the experience.

If the 500 is running good don't bother trying the 600 top end

But if the 500 is blown or in need of rebuild and you can get the 600 top end cheap go for it

But the again find an 800 instead :div20:

Dont waste money on the pipe, the 5's are peeky and really hard to keep in the sweet spot for a pipe. Gas milage first, Jet down to 340's and install Q-4 480 needle jets in place of the Q-2's. the 5 was lean in the middle and the Q-4's will take care of that, and milage should come up to 100 miles per tank. Make sure the carbs are synced while your there.
Gear down a tooth on top, stock chain will work. Good starting point on clutching, 57/50 helix, red/white secondary and Polaris 10MB 47.5 grams or 10m5's 49.5 grams depending what rpms your pulling. The 5's liked 79-8000 out of the hole and no more than 84-8500 on the big end. Good luck.

there was a huge difference in power when I went from the 500 to 600. The 600 got alot better gas mileage also since i didnt have to hold the damn thing wfo all the time to keep up with bigger sleds.

I had a 98 ZL 500 that ran real good , I could stay with a buddies 580 , I wouldnt mess with it unless the 500 us junk, and if it is go spend the a little more cash and put a 700 Hooper in the sled you will not be disappointed, I have one now and I can run with about any stock T_cat.

I HAD A COUPLE OF ZL 500s..310 MAINS ..I KNOW THAT SOUNDS LEAN BUT I NEVER HAD TROUBLE ...600 SEEMS TO NOT BE AS HIGH STRUNG ...BEEN TOLD BY PEOPLE THAT I THINK KNOW ALOT TO REPLACE DRIVE CLUTCH EVERY 1000 MILES ..SEEMS THAT THIS STYLE MOTOR IS HARD ON CLUTCHES ...

The clutch problems is more due to the higher engagement, clutch is usually good for 3000 miles. The 500 will take out a 580 easily.

NEWS FLASH........ they quit making the 800 :frech32:
if your trying to beat another 6,get a 7.
if your trying to beat a 7,get a 9
you will never go as fast (now) as Kirk used to.......

:tease: Gee Batman you sure are a smart one

i went down the same road with my 500 98 zr , i ended up putting a psi pipe power breather clutch kit that was a good sled, later i burned down the sled then had it sent to fett brothers to bore it out to a 680 , wow what a nice sled now with good gas milage to boost like 12 miles to the gallon. and it always try to rip my arms off all the time.. had good luck with my sled and use the stock pipe.

I think that i would go ahead and do the top end swap. I have a 99 zr 500 and a 99 zr 600. and the 600 is a way stronger. I can't say that i don't like the 500 in certain conditions it is more fun to ride. I would make sure that your center to center is dead nutz on. and make sure your belt is shimed out on the secondary. I like to have mine about 90 thousands out of the clutch. Keeps a good shift off the line. Some of these sleds seem to get moving then have a dead spot for a couple second when you are starting from a dead stop. I personally like the higher engagment to. 5500 rpms, I use this on both sleds. Pm me and I can share more info on what weights and springs i use if you are interested.

I have to agree with arcticranger..had the same happen when I went from a 99 zl 500 to a 99 zl 600. Mine were always left stock though. That 500 was really picky about the belt deflection also.

Once again guys thanks for all the input. :cn: I didn`t realize there would be such a difference in opinions on what to do. I thought the 600 would be better than the 500 because it would have more HP and CC`s also thought it would be easier on fuel, because I wouldn`t have to be full throttle all the time. If I had the extra money I would put bigger motor or big bore kit ( HOOPER,BLACK MAGIC OR D&D), but can`t afford that at this time, so I will have to work with what I have. Still appreciate all the information and help from all who have responded,and any more info is greatly appreciated. :beer2:

By the way guys my sled has less than 3,000 miles on it. I purchased this sled 2 years ago and have put about 900 to 1000 miles on it. As you can tell I don`t get a chance to put too many miles on it. Hopefully this year I will be able to put a few more miles on this year. Just thought I should give you guys a little info on the sled.


:fluffy:

Hell,, if thats all the miles and it works good I wouldn't touch it, different if it had to be taken apart anyways, I don't know if a 600 would be much easier on fuel without PV, it's the rev"s that suck the gas, I can run about 110 miles to a tank with mine, as far the diff in power I was never that impressed those years 600's.

I would just leave it stock if you dont get out riding that much. Once you start add pipes and what not you will have to spend 1 or 2 rides screwing with it until you get it set up properly.

i had a 00 zl 500 added d &d pipe, silencer, clutch kit, and a power breather re jetted the carbs and i could take my buddies 600 piped /clutched sled by 2 or 3 sleds when we would line up

my 99 zr 600 efi has a dnd pipe and chip. I did my own clutching. It will run with a 03 f-7. I wouldn't say i can beat it in a drag race. But I was right on his AZZZZ

Thanks again, to all that have contributed to this topic. :div20:

:fluffy:

Okay guys I`ve decided to leave my 500 the way it is. So I now have a 600 top end for sale if anyone knows of anyone looking for these parts. I have the cylinders(non Valved),head,pistons,c-clip and rings. The cylinders are newly replated, the pistons,c-clip and rings are brand new(still in the box) and the head is in excellent shape. I just tried to post pitures, but my camera won`t load them into the computer for some reason. I`d like to get $650 Cdn. + shipping, if your interested you can e-mail me at camarrow_69@hotmail.com. :cn:

Thanks Again Guys for all your help,
Jim :beerchug:

Lots of guys have said some helpful things on this thread. I have a 99ZR500 with black magic twin pipes, custom clutch setup and she hauls AZZ pretty good. Also agree with Acrticranger that our sleds work best engaging at 5500 RPM's. I have amazing throttle response and no lag whatsoever. If you decide to do anything to it, that's my advice to you as this setup really wakes up the 500 motor!

ttt