Finally got out to try the 800 transplant on Tuesday and she ran like a top. Just needs some clutch work. I know there have been many discussions before I just wanted a little info on my setup. It is currently stock 01 clutching and is over revving to around 8k not sure what the top would be as I never put it all the way to the bar as it is just getting broke in. I have heard a lot of good things about Goodwin kits but was trying to save a couple bucks this year and put a kit in it next year. If I add the 70.5 weights that were stock in the 02's would that solve the rev issues? What hole should I have the secondary spring in?

I also have a Powerbreather and have not installed it yet. Is there a noticeable difference? What should I do for jetting or carb setup. Currently running 420's. Where do you mount it?
Or should I just bag it and take the shelf and horns out. I just don't want to have to worry about rejetting and reliability issues.

Anyone try the D&D y pipe, heard it added 5hp but curious if it was worth the $$ (next year project).

Thanks for all who helped get his beast converted!

What were the stock weights and the helix and spring your running now but it does sound like you will need more weight...and what is the projected rpm target?R2R

Primary purple spring, weights 66.0 grams, helix 55/53 and a red white spring I think, might be yellow though. From what I have read engine makes peak around 7200 to 7300 rpms and should peak around 7500ish for best results. Thanks

So the engine is still basically stock,,seems like alot of rev's to nail down,,yeah, I would throw the weights at it to see what it does,, what's the diff from 01-02 that it needs 4 g heavier weights,,R2R

i have 62/54 EPI helix that you can have cheap? also a straight 49. used on 2001 ZR800. interested?

ps i may have another need to look.

49 would be to much,,over reving now,,

someone told me the cdi box is better on the 2002. The only other change motor wise is crank and mabye servo cycles diff RPMS dont know for sure.

Kinda looks like they make power at a diff rpm,,heavier weights and red/white spring in 02,, bring down the rev with weights then raise it with a spring,, anyone know if both these years rev at the same rpm? R2R

stock 7500 01 and 02

yea the 49 was used for a while on twin Magic pipes... along with a few other combos.

Anyone ever line these two up to see which is faster,, 02 looks stronger in the mid,, 01 may have better top ,,interestering,,,R2R

Basically throwing the 70G weights you would almost need to leave the yellow spring in to drop rpm,,why would it be turning 8000 in the first place,, what gears you running??

FYI
Stock '02 ZR800 clutching;
70.5 gram wieghts
Purple primary spring
Red-white secondary spring in center hole
55-53 Helix.

Many have found that going to the ZR900 71.5 gram weights works better by pulling down the revs from ~7500 to ~7300/7400. Most dyno numbers seem to confirm 7400 is the sweet spot for the 800 twin.
60/52 helix adds some extra midrange punch for added trail riding fun.

Problem is he needs to drop 500rpm and 1.5g more going to a finish of 52 from 53 won't really bring it down enough i wouldn't think,, need to try it to see I guess,,,R2R

I think that they just got it a little more dialed in?

Stock gearing 24/39

I guess the weights would be the thing to try see what happens,, R2R

Stock 02 clutching:

70.5/purple

55/53 - cat red/white #3

or even better

72.5 speedwerx Q

epi - yellow

59/53x speedwerx, cat red/white #3

good luck

Goodwins kit for that sled is mint right outta the box.