Ive got a buddy whos got a 2000 ZR, thinking about swaping in a ZRT or Tcat motor.......whats it going to take to make this happen, from what I understand hes going to need the bellypan and hood from a tripple, other than that what else has to be changed, also whats better for a trail motor.....wants to mod it alittle but still have a trail sled. some guys are saying the ZRT 800 while some others are saying go for the T-Cat 900 or 1000......Im a Polaris guy helping out a buddy so if some one could shine some light on this I thank you in advance!!!!!!

I would say if u want a little less weight go for the zrt motor, if u want a little more power and a little more weight go for the tcat.

The 800, 900, 1000 motor is the same motor. The 1000 has a bigger hole in the cylinder wouldn't that make it lighter ? In all reality I think there all the same weight.

The zrt 600 is lighter. differant motor. no balance shaft.

Zrt 800 and 900 tcat motors are identical besides topend bore. the 1000 hase a shorter stroke and bigger bore. its easy to swap from a 800 to a 900, just change topends. The 1000 topend cant be as easily put on a 800 900 bottom end due to the stroke differance. There are MANY bigbore kits for both bottom ends.

The 800 zrt parts are cheaper to get because most people go bigger and take off all the 800 stuff. tcat 900 was the way this motor was origanoly designed and is a verry dependable motor. they debored the 900 to make the 800zrt. that 1000 tcat is more wanted by lake racers so is more expensive to get.

The case, counterbalance, cdi,and stator are tha same.
You will need to figure out what electronics to use. either the newer 3d cdi or older style cdi. TM or VM carbs ? Aftermarket or stock pipes ?

The upper jack shaft is longer on a zrt 800 than a zr. You may want to upgrade the drive axle to a 4 driver insted of the 2 driver w 2 wheels.

You will need the hood R+ L bellypan,front bumper and I think the cowl pieces are differant and mabe the center bellypan.

There are after market pipes that fit under the hood of a zr with a tcat motor.

It can be done,not as easy as you would think.The motor mounts are different,clutch offset and center distance have to be fitted.Pipes will need work to fit,cooling issues among other things.I built a 98 zr500 with a 1000cc T-cat race motor,220 hp on dyno-tech dyno.Set up for outlaw ice drags.Lot of work but one ride made it worth it!

The swap is actually very easy and does not take very much time at all. Should be able to be done in a day/weekend. I have done a few and am in the process of doing another right now. For motor mounts your chassis has all the holes already predrilled from CAT. You just have to tap two of the predrilled holes to mount a stock twin mount to the farthes set of holes on the mag side. For the back mounts they are the same location on twins and tripples and will go right in easily it is recommended that the rear pto mount be reinforce or a strap built to hold the torque of that motor in line with the clutches. For the clutching because the tripple moves close to the belly pan side you just have to add about 3/4 shims behind the secondary clutch on the jackshaft to correct the parallel of the clutches. Everything else is straigth forward like any engine swap. If you already have T-Cat pipes for the motor and do not want to fit or buy pipes you then will have to go to the wider tripple front end. T-Cat belly pans,hood,center belly pan/skid plate. By the time it takes to change and buy the parts to swap to the T-Cat plastic you can probably pick up a set of already fit pipes for the narrower ZR/1M/KK chassis. By staying with the narrower ZR chassis you can still have that narrow stance for better manouverability in the tight stuff and also keep the weight down and keep the narrower ski stance. PM if you have more questions have experience doing the swap and have been around the swap all my sledding years. I live 1/2 from Chad Rebec/Cr Racing and that is one of his specialties putting the big tripple in the narrower,lighter more nimble ZR/1M/KK chassis. I also have a set of brand new Jaws pipes and cans that are ceramicoated for the tripple swap in the ZR/1M/KK for sale. Greg at Jaws has these pipes in stock for that swap of the tripple in the ZR chassis. Jaws also makes the most hp on those motors and work very well and would not recommend any other. Have seen dyno runs of differnet pipe combos, greg also is the only company that has sets in stock ready to ship,most the other companies have to fit them before sending them out. Can send you pics of a couple of my tripple mods in the KK chassis. Let me know.

good mod guy!!!!!
my question is ,how much weight less compare to t-cat....

I have not had it on a scale,my trail sled is a ZRT800 with a 1000cc big bore.my guess is 50-75 lbs.The zrt is a 96 with a steel bulkhead.
the ZR is all aluminum and has the ETT tunnel.I built custom motor mounts for strength.my carb intakes are polaris units costom welded on the T-cat crankcase with billet intake manifolds with 48mm Lectrons.220hp on dyno-tech dyno.