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ZRT 1107

7K views 7 replies 4 participants last post by  blaine  
#1 ·
Thinking about makeing my 99 zrt into a d&d 1107. Just wondering what else would have to be done to the sled to make it preform right. I know all the engine work, but do i have to bore the carbs? Fuel pump? clutching? gearing? what about timing? any help would be appreciated
 
#3 ·
Thinking about makeing my 99 zrt into a d&d 1107. Just wondering what else would have to be done to the sled to make it preform right. I know all the engine work, but do i have to bore the carbs? Fuel pump? clutching? gearing? what about timing? any help would be appreciated[/b]
I have built, ported and set up a lot of big triple big bores,
The 1107(85 mm bore) needs to made out of 900 cylinder's if you are going to trail ride it, The 800 cylinder is to thin to trail ride with a bore that large and you lose the rear boost port. If you only have 800 cylinders I would not go any larger than a 1055(83mm bore) with the 800 cylinder.
If you have the stock CU2545 cdi, you will be good with that and don't put a key with this cdi box.
The stock fuel pump has plenty and rack flatslide carbs run very good with a big bore
The best gearing is 23/40 for the trail or 25/38 if you like the high speed runs.
They clutching depends on how you are setup???
Mike
 
#5 ·
How fast does the clutching go? I remember last year on the lake sled didnt seem to want to go much over 100.

Here are your options with an 800 cylinder.

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.

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 (must had bigger then 800 cylinder)
*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).
 
#6 ·
Well actually the cylinders and heads are put out by D&D racing. But the stock carbs can be used, without boring? and will there be any cooling isues? Can I use the stock 800 exaust? Thanks for the info snow800, and I did use that clutch setup you had given me thanks a lot.[/b]
Have you ran it with the clutching????
You can bore th carbs, but I don't recommend it on a trail sled. I have made many sleds fast with stock carbs.
All sleds have cooling issue's without good snow, You defenitly need a water temp gauge on a big bore.
Keep one eye on the trail and one on the gauge, if it starts to get warm, slow down get off the trail, do a couple pumps on the throttle
to spin the track in the fluffy stuff and get back on the trail and you are good for a couple more miles.

It will run with the stock 800 exhaust, but not to potential. If you are going to run 800 stock pipes, The stock 800 silencer is very restrictive, I would run a MBRP or D&D can.
Mike
 
#7 ·
I have built, ported and set up a lot of big triple big bores,
The 1107(85 mm bore) needs to made out of 900 cylinder's if you are going to trail ride it, The 800 cylinder is to thin to trail ride with a bore that large and you lose the rear boost port. If you only have 800 cylinders I would not go any larger than a 1055(83mm bore) with the 800 cylinder.
If you have the stock CU2545 cdi, you will be good with that and don't put a key with this cdi box.
The stock fuel pump has plenty and rack flatslide carbs run very good with a big bore
The best gearing is 23/40 for the trail or 25/38 if you like the high speed runs.
They clutching depends on how you are setup???
Mike[/b]
Pretty much what Snow800 said. My Ron Hunyady 1107 seemed to run out of gas after 500 feet last year. Not sure exactly why. This summer I repalced all lines (carbs have the added "T" to accept 2 fuel lines), fuel filter, checked the hose/pick up in the tank and put a high volume fuel pump on it. Carbs are bored out to 41.5-ish. I run 540 mains..shouldn't be running the pump dry, but not sure what was causing it to run out of fuel. I didn't have time to check it last year.
 
#8 ·
Well actually the cylinders and heads are put out by D&D racing. But the stock carbs can be used, without boring? and will there be any cooling isues? Can I use the stock 800 exaust? Thanks for the info snow800, and I did use that clutch setup you had given me thanks a lot.[/b]
Bore the carbs. Can't use stock exhaust unless you want to get outrun by tuned T-Cats.

Yes you need to add cooling.
adding cooling to a Cat


Here is the water temp sensor and video in how to install it.
Temp sensor link and video link