which clutch and gearing setup is good for a zr500 for agressive trail and also one for a 660drag??

I know this is old but I've been trying to find this information as well. I need to rebuild a 99' ZR primary clutch. Should i replace all the internals with new stock pieces or does a "clutch kit" replace the internals with better pieces? Sorry fo rthe noob question but I have zero experience with these clutches. I understand the principal pretty well but exactly what pieces to replace and what weights/springs to even start with is all greek to me.

I know this is old but I've been trying to find this information as well. I need to rebuild a 99' ZR primary clutch. Should i replace all the internals with new stock pieces or does a "clutch kit" replace the internals with better pieces? Sorry fo rthe noob question but I have zero experience with these clutches. I understand the principal pretty well but exactly what pieces to replace and what weights/springs to even start with is all greek to me.
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great proven setup for 98/99 zr500 & zr600's.
huge difference over stock setup.

cat orange/white primary
polaris 10 weights (51.5g) 600's can pull a little more.
cat red/white secondary (2nd or 3rd hole)
58-50 helix

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cat orange/white primary- easy enough

polaris 10 weights (51.5g) 600's can pull a little more- By Polaris 10 weights do you mean weights for a polaris clutch? From a polaris dealer? (I told you I know very little about the actual parts, only the theory behind it- you can only get so much from books and internet articles.)

cat red/white secondary (2nd or 3rd hole)- would that be 2nd or 3rd from the left?

58-50 helix- I assume this would be a multi-angle helix?

Thanks Ed! I've been searching for something like this. I need someplace to start and didn't have a clue. As always, SWRules

Cut
Print
Running to dealer

cat orange/white primary- easy enough

polaris 10 weights (51.5g) 600's can pull a little more- By Polaris 10 weights do you mean weights for a polaris clutch? From a polaris dealer? (I told you I know very little about the actual parts, only the theory behind it- you can only get so much from books and internet articles.)

cat red/white secondary (2nd or 3rd hole)- would that be 2nd or 3rd from the left?

58-50 helix- I assume this would be a multi-angle helix?

Thanks Ed! I've been searching for something like this. I need someplace to start and didn't have a clue. As always, SWRules
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yes the plain old polaris weights. you can get them from a polaris dealer or many aftermarket dealers (i know goodwin performance sells them)

secondary spring you can start in the 2nd hole from the left. you may notice better performance in the 3rd (center) hole. try both and see for yourself

58-50 is a mulitangle helix you can get from just about any aftermarket dealer (dalton industries, d&d etc). not sure if your local cat dealer will have them.

sled should engage around 5K rpm and peak 83-8500 rpms. even though cat lists peak hp at 85-8700 rpms, these sleds pull harder if you keep rpms just under 8500.

good luck.

Great info thanks!

I really had no starting point. The setup in the clutches right now is terrible. It falls on it's face off the line and is terribly hard to rev. I won't know if it's terrible clutching, broken spring, worn parts until I get in there and tear it apart. Again, I can't say enough THANK YOU!
Joe

if you have trouble finding a 58-50 helix, i know cat makes a 57-50 that any dealer should have. very little difference between the two.

I transferred this post to the AC section as possible a better place for this post:

http://www.snowmobileworld.com/forum/index...c=65310&hl= (http://www.snowmobileworld.com/forum/index.php?showtopic=65310&hl=)

Sorry fo rthe duplicate.



Ok, I'm at a crossroads and hopefully you guys can help me out.

Facts: 1999 ZR 500 efi stock

The setup above using the polaris weights, cat springs and 58-50 helix will cost $160.92 from Goodwin performance. (only place I can get everything at once which cuts down on shipping.

I see D&D has a clutch kit for $179.55
Black magic has one for $179 (same price)

Question 1: Does a "clutch kit" typically include weights, both springs, and helix?

Question 2: Anyone have any experience with either D&D or Black magic specifically on stock small block ZRs? Does efi make any difference in clutching?? I see BM has carb and efi specific kits.

Ok, I guess that's 3 questions....



As a side note: I took a compression reading last night and am happy to report 145 & 135psi (w/i 7%) so I can wait till next year to drop $200 in pistons!


As usual......HELP GUYS?!
Joe