I bought a used 2002 ZR 500. I was wondering what the max. operating RPM is and when the clutch is suppose to engage. It engages at 4000 RPM and max RPM is 8000 to 8100. I rode it a little last weekend and it only got 9 mpg. I was hoping for a little improvement. I cleaned the APV already, they weren't sticking. Any info would be appreciated.

Those RPM's sound about right. I'm just sorry to say that the 500 suzuki engine really loves its gas. If your worried about running out of fuel on the trail then look into getting a Tour Buddy.

not sure whats in that sled for a clutch setup but i had a 98 440 snopro and we got 14-16 mpg with it not the same but fairly similer, 19/40 gears, comet a1 weights purple cat drive spring 62/54 helix in back with a red white driven spring all around good trail setup, if youre sled has that green driven spring thatll kill mileage take it out and throw it as far as you can into youre neighbors yard and try a red or even the yellow spring itll pull youre cruisen rpms down some. good luck, thanks for buyin a cat. SWRules

I put a red primary spring on my 98 ZL500 and gained about 3MPG.I'm about 13-14MPG now.Also dropping the needles a notch helped too.A 97 hp 500cc engine is gonna burn fuel.Hp doesn't come cheap! SWRules

I have a yellow spring on my drive and a red spring on my driven. The helix is stock. I am waiting on a CD ROM service manual, it is not in yet. I don't know what the helix is yet.

Im running a D&D clutch kit along with their powerbreather, carbontech reeds and gearing in my 2002 zr 500 and it really rips. Mine isnt very good on gas either even when it was completely stock. I would recommend the D&D clutch kit. It works excellent.