Is there a way to use a 2000 ZRT 800 bottom end an make it into a 1000 with out changing con rods ??

Auggie

20mm wrist pins vs 22mm wrist pins.

big bore cylinders with 20 mm wrist pin pistons there are some on this site or amsnow for sale

Yes you can, You have 1 of 2 choices, You can use the ZR 700 pistons and shim the 1000 Tcat cylinders .The second choice is a Wiseco, if you look on Wiseco's website in the 1993 to 1997 Tcat 992 overbore, that piston is a 80.5 bore that is a 4 mm overbore,
they have a 4.5 mm overbore, part number 2403M8100 that is a 81 mm bore with a 20 mm pin and will go together without any problems.
Mike

Lookin' for a little more gitty-up Auggie?

Yah Jim, I did a rebuild for this buddy of mine who has a 1998 T-Cat he uses for speed runs (see pic's) and he picked up that blown engine (see my other post and pic's) for spare parts. Well it turns out he hasn't needed any parts off of it so he gave it to me. I am thinking that maybe my best bet would be to swap this whole engine for a 900 top end. Any takers out there ??

Nice T cat.I got onr just like it. Mine is bone stock.Is yours stock? I want to use mine just for speed runs as well.

Here is some extra info from articchat

1000 has a 64.6mm stroke and a Ø22mm piston pin
800/900 has a 65mm stroke and a Ø20mm piston pin
Bigbore:
800 cyls can be bored to about Ø83mm->1055cc on 65mm stroke
900 and 1000 cyls can be bored to Ø85mm->1107cc on 65mm stroke, 1100cc on 64.6mm stroke. Some have bored 1000 cyls to Ø86mm->1133cc on 65mm stroke (look at the CPC site) but the cylinder skirts are thin enough at Ø85 bore so this could potentially become a problem. Could be solved by using tigershark 1100 cylinders but that requires block machining to fit the larger diameter cylinder skirt.
If you go over ~Ø83mm bore on any of the 800/900/1000 cyls it is recommended that you fill the std inner o-ring groove with TIG-weld and have a larger diameter inner o-ring groove cut in the cylinder tops and then have the cylinders turned flat to make a nice finish, normally you only need to take off about 0.1mm/.004" to get them smooth.
The blocks are virtually identical on 800/900/1000 so you can use a 800 crank in a 1000 block if you would wish.

Common piston choices
65mm stroke:

993cc
*80.5mm Wisecos listed as 4.0mm overbore for Thundercat 900. Wiseco part#: 2403M08050

1005cc
*81mm Wisecos listed as 4.5mm overbore for Thundercat 900. Wiseco part#: 2403M08100
*81mm Wildcat/ZR700 pistons, need to add a 2mm/.08" spacer/shim under the cylinders to compenate for the (2mm) higher pistons. Available from Arctic cat as cast and wiseco #2370M08100 as forged.
*81mm Kawazaki Watercraft JS 750 pistons. These are almost totally flattop pistons (only 0.8-1.0mm dome height) so you need to recut the heads for this. Available from ProX pistons as cast and wiseco #623P4 as forged.

1030cc
*82mm Wildcat/ZR700 pistons, need to add a 2mm/.08" spacer under the cylinders to compenate for the (2mm) higher pistons. Available from wiseco #2370M08200 as forged.
*82mm Kawazaki Watercraft JS 750 pistons. These are almost totally flattop pistons so you need to recut the heads for this. Available from wiseco #623P8 as forged. Actually, wiseco has these in 80/80.5/81/81.5/82/83/85/85.5mm sizes.

1055cc
*83mm Kawazaki Watercraft JS 750 pistons. These are almost totally flattop pistons so you need to recut the heads for this. Available from wiseco #623P12 as forged.

1107cc
*85mm Kawazaki Watercraft JS 750 pistons. These are almost totally flattop pistons so you need to recut the heads for this. Available from wiseco #623P20 as forged.
*85mm 1107 available from D&D, Black Magic and others. Custom ordered Wisecos (not flattop pistons).

1120cc
*85.5mm Kawazaki Watercraft JS 750 pistons. These are almost totally flattop pistons so you need to recut the heads for this. Available from wiseco #623P22 as forged.

1133cc
*86mm Wildcat/ZR700 pistons, need to add a 2mm/.08" spacer under the cylinders to compenate for the (2mm) higher pistons. Available from wiseco #2400M08600 as forged.

64.6mm stroke:

999cc
*81mm std Thundercat 1000 pistons. Crack prone...
*81mm Wisecos #2394M08100

1100cc
*85mm Thundercat 1000 4mm overbore, available from wiseco #718M08500 as forged.

Yup Jim, he runs it in the stock class and Johnny Park all I can say is WOW and AWESOME I will print that info.

Auggie

I have a complete 900 top end for sale if your interested.

So I'm thinking I would like to do something similiar to this, but I have a few questions as well. So I want to go with putting t-cat 1000 cylinders w/ wildcat 700 pistons but where can i get the 2 mm spacers needed to go under the cylinders? Next question is can I use my 800 heads (what is the cumbustion chamber of these heads and 1000 heads). If I can't use the 800 heads as stock what do I need to do to them, because I would really like to have the 800 on top ?

www.ddracing.com sells them, but they are not on their site, call them.
You don't need the shims, buy Wiseco pistons, part number 2403M8100 that is a 81 mm bore with a 20 mm pin and will go together on the 1000 Tcat cylinders without any problems. If you the 700 ZR pistons with the shims, the dome of the piston is greater than the tcat piston and the combustion chamber of the head needs to be recut to make up for it, you will also need to shave the heads to get the compression back
where it needs to be. If you buy the piston I listed above, you just put the piston on and put the stock 1000 cylinder and head on it and you are good, no modifications.
Mike

Say I use them pistons that you recommended, I really want the engine to appear stock. So what needs to be done to the 800 heads so that they will work with the 1000 cylenders?

There is a guy in my area(SE Michigan) that does all my stuff, you could ship the heads to him.
You just need to machine the combustion chamber of the 800 head to the same as a 1000.
Mike

great info. how do i save this stuff too my computer for future reference. yes i am computer illiterate. thanks

Select the Text with a Click and Drag - Then right Click on the Text - Select Copy- Then open a Text Document Like NOTE PAD and Re Click on the Emtpy Doc. And then click Paste