I am looking for some advice from those who have or had an ZR800. What clutch setups did you run? helix's/springs? Or any other recommendations. (Looking to do aggressive trail riding)

I know of good heel-clicker set-up if you are interested

I had Micro-Belmont build my clutch setup. I have 25/38 spline gears, and they gave me a 62/50 helix, purple primary, and red secondary spring.....this sled is hard to hook up with just over 100 picks in the track....

WHEN I BOUGHT MY 2002 ZR 800 EFI LAST YEAR ,THE GUY HAD A BLACK TRAGIC CLUTCH KIT IN IT , I PLAYED WITH THEM REAR HELIX SHIMS ALL LAST YEAR ,NEVER COULD GET IT TO WORK RIGHT , JUST BOUGHT ONE FROM D@D ,SLED HALLS ASS NOW ,WELL MONEY SPENT .(185.00 $ )SLED IS BONE STOCK ,RUNS RIGHT AROUND 7500 TO 7600 ,THATS A LITTLE HIGH BUT I HEARD THE TACHS RUN ABOUT 200-300 TO HIGH ,SLED PULLS HARD FROM BOTTOM TO TOP ,VERY HAPPY :div20:

My '02 800 ran, with only a gutted airbox, very well with just adding some helix to the clutching setup. I think (don't shoot me if I'm wrong!) I went from the stock 55/53 to a 60/52. If my numbers are wrong the bottom line is I added a few degrees up on the high number and a few down on the bottom. It just pulled a lot harder and went a lot faster!

I have heard of gutted airboxes . However what is it that you actually do. Remove the toolbox ????

Gordonh8r

They are taking the shelf out with the two lil air horns in it. I left mine in but I run a power breather. I feel the shelf helps control the air better than letting it bounce around. Get a power breather if you want more air flow, mine works great.

IF YOU HAVE A EFI , YOU CANT RUN A POWER BREATHER !!!!!!!!!!!!!!!!!!

Off the main subject did you do any jet changes with the breather????
put one on my 01 800 went to 430 mains from 410. rode it tonight. plugs still look lean!!

Is it still ok to gut the air box with an EFI?

I'm still at 430's but I also have reeds and a key. My sled is fat, my plugs look like somone pee'd on them so I have to make an adjustment. I'm gona try the 9DFH-58 needle and the 410 jets next.

Maxx4,
If your plugs are pee yellow (lean) with 430's don't go to 410's. Go richer to 440's and seek a cardboard brown plug colour, or darker for safety.
The 800 twins are not finicky about jetting. Being too lean will cost you big when it blows but not give you more power beforehand. Not worth the risk.

I've got the heelclicker also & after almost 2 seasons I'm still trying to figure them out!! Almost ready to pitch them & go back to stock....so what's yer set-up??

I've been working with my Heavy Hitters for the past 2 seasons and they seem to work well in this sled. I have to admit that my 02 800 EFI has been the hardest sled that I have worked with to get a good consistent every day clutch set-up. Even with the EFI it seems to be affected enough by temperature change (over 15-20 deg.) With the heavy hitters I am able to make the adjustments if conditions change. Ie. if temps are 15 degF or below I run weights set up at about 74 gms, (4.2 bolt in the tip) and if the temp is above above 25 Deg. I change the tip weight to 2.6 gms) and it seems to be spot on...

Running a Goodwin kit in mine, nice improvement over stock with zero negetive issues.

Rick.