if i change the bottle can i take the zr heat exchanger setup (front and back exchangers and tunnel rails) and put it into my 96 zrt 600??? or is there any other setup that will work???? it overheats on the hard pac seems like a bad place for the exchanger not enough snow being thrown up in that spot...any ideas would be great...

Newer ZR's have a one piece front exchanger built into the bulkhead but a 96 is essentially identical so it wouldn't need to be swapped. The newer ZR's don't have a rear exchanger, just a tube that connects the 2 side rails together.

You could add the 2 rails for better cooling since your 96 already has the rear exchanger, it would just take a bit to figure it out.

If you are running your 96 on hard pack trails and running into cooling issues, there may be something else wrong.

trails is ok even hard pac but the river or lake overheats in 10 miles ok if snow is soft...

Add a ZRT heat exchanger to the rear. Here's a link about it with pics.

Added heat exchanger

I thought the 96 already had the rear exchanger.

For added cooling the tunnel exchangers could be added, or I've heard of ice scrapers but never used them.

If I remember right, none of them have a rear exchanger. My buddy has added many of them to all years of triples. It is the 1st thing he does before he mods it. That way you don't have to cool off the motor with gas.

I was just checking out browns and it shows a rear heat exchanger for the 96 zrt 600. I know my 95 zrt 800 definitely has one
I'm kev off achat btw if you haven't guessed yet. I'm curious what you mean by using gas to cool the motor off?

Side note: I have a 1998 pantera rear exchanger if anyone needs one.

it has a rear exchanger thats the only way i can cool it by busting chunks of snow lose and placing them on the exchanger and they melt fast!!!!!!!!! if I use the rails like my 580 has will the rear exchanger still work ok?? I would just run a line out of the rail into the exchanger and back into the other rail right?????? thanx for the input guys

I have to plead ignorance on the 600's. I've never worked on one. Like the Arcticchat link says, we all added a heat exchanger to the rear of our ZRT 800, 900 and 1000 sleds for added cooling.

As far as the statement "using gas to cool the motor off", if you took identical modified motors (everything else being the same too like pipes, heads, timing, gearing ect..) we can run smaller main jets with the added heat exchanger in the rear of the sled. Other guys run larger main jets because the stock cooling systems can't cool off the motor (run at the stat 120 degrees) especially in marginal snow conditions. If I remember right, there were guys running 480 to 500 mains in the same motor that Ron was running 430's (Ron's D&D 1000 if I remember right). There was quite a difference. Ron got over 12mpg with his D&D 1100 in Canada a few years back. Of course he had it geared up a little bit and re-clutched it to run 5000-5500 rpms going 55-70mph.

Ron's big bores he makes now run 540 mains so that gives you an idea of how hard his motors run because they are using all of it. Granted the triple float bowls aren't that big. I had a stock fuel pump on my 1107 he ported for me and I ran out of fuel after 550-600 feet. I am putting a high volume fuel pump on it for next year. Everyone in our group runs high volume fuel pumps and our sleds run at 120 to no more than 130 degrees. People think I'm crazy, but if my sled gets over 130 degrees either something is wrong or I'm running on no snow and i will shut my sled down.

Hopefully someone who's done it could add some info, but from what I understand you are correct. It should have 2 hoses running under the seat to the rear exchanger. You'd remove those hoses, then cut slots in the tunnel under the seat and rivet the new rails on, and then find hoses to match up to the rear and front.

when i did my 95 zrt 800 i removed the coolant tubes from under the seat and replaced them with a heat exchanger from a 93 thundercat.all you have to do is cut a long slot where the tubes used to be and silicone and rivit the new exchanger in place.it is the same legnth as the tubes so the hoses will slip right on.now you are running 3 exchangers instead of the 2 stock ones,it helps to keep the big tripples running around 120*total time was less than 1 hour to do.

would you have a picture of that mod it would be a great help..

i parted out the sled,i still have the tunnel but the exchanger is sold.i will get a pic and show you what i did and where it goes.

here is a pic of the slot i cut out,the exchanger from a 93 thundercat fits perfectly where the coolant tubes run all you have to do is take the tubes out and cut a slot for the new exchanger.the hoses that connected the tubes to the front and rear exchangers will fit on the the 93 exchanger perfect.all you are doing is just eliminating the tubes completely.you will have to move the tunnel protecter over a little because it runs right under the slot that only takes a couple of minutes though,hope this helps if you have more questions just ask.BTW this is a mod i learned from tcatsteve.