Today I bought a really cheap 98 zr600. The guy I picked it up from was an aircraft mechanic, it is a stock sled, every season he cleaned the clutches, and the carbs. Last season it had the clutches rebuilt, bearings in the skid all replaced, bearings on the jackshaft replaced and the fox shocks rebuilt. He also honed the cylinders and put new rings in. 200 miles later the bottom end let go (LH rod bearing is mangled). He had the jugs off (engine sitting on bench). It ruined the one jug (well it is scored) piston is damaged, and there is some damage to the head (looks like it might scotch pad out).

Now. I'm a mechanic by trade, but honestly, I've never gone any deeper than a Jug on a 2 stroke.

He has a set of the "updated" stock pistons sitting on the bench. So I'd need to find a jug, rod, and maybe a crank. The case wasn't cracked but it did have a few scars from where the pieces of bearing hit. Other than this the sled is in great shape.

Or do I just find a cheap used engine?

So what would you do? I don't want to spend alot of money on this endevor, just somthing to get it up and running for the season and maybe the season after.

I have heard of the 98's having problems with the pistons and ports. Would a 99 engine fit?

Sorry for the noobish questions.

Jordan

i would just go to a sled salvage ward and see what is cheaper to do

Anyone know of a good yard in Manitoba?

Jordan

go to yellowpages.com and see what you got then call someone up

do you need a new jug, or can you simply have your renicked?? if you can have that done and the crank isnt bad, I would rebuild,,,

Hi there I have a used crank and 1 cylinder in Terrace Bay Ont. it has 4000 to 4500 on it i bought its out of a 99 zl 6oo make offer i will add picks

Hi there I have a used crank and 1 cylinder in Terrace Bay Ont. it has 4000 to 4500 on it i bought its out of a 99 zl 6oo make offer i will add picks
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Will this engine fit? Are the ZR and ZL the same engine? Can I mix and match these parts to make one engine?

4500Miles... Is that the time bearings start to need checking etc?

Jordan

im 99% positive they are the same engine the ZR just had nicer suspension parts then the ZL and are the ZR engine EFI what make no difference on the restof the engine though just how the fuel gets there

im 99% positive they are the same engine the ZR just had nicer suspension parts then the ZL and are the ZR engine EFI what make no difference on the restof the engine though just how the fuel gets there
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Thanks Freddie, you are a great source of info!

Jordan

it freddy with a y but you not the first they spelled it wrong on my report card once . Just looked it up and they are the same engine(98-00) so good luck buddy and hope this all helps. the 01 and up engine is different so stay away from those guys

Sorry, FreddY.

It will be a conglomeration of parts, but as long as it works, I'm happy. I guess the jugs would be the same also? Since its a 99, it would definatly not have the poor designed jugs correct? I couldn't mix my one good jug, with one of the 99 Jugs? I guess if my one good jug is the "later style" it should be the same.

Where do you guys find litature on these engines? I'll need a rebuild manual etc. The owner does have a photocopy of most of the engine stuff from the dealer, torque specs. I didn't look closely through it.

This will be my first sled in quite some time. Hopfully I'll get the wife into the sport. Then it will be good ol' fashion family fun.

Jordan

i just looked a the piston size bore stroke that all i did same engine from 98 to 00 then after that the 01 and up is a different 600 engine (has exaust valves) the good one off the old on and a good used one should work together
i looked at wiseco piston chart to figure it out but as for the manual go to the dealer and ask would be the best bet good luck

the crank from the 99 zl will fit your 98 zr. Both the same motor. The zl suspension is a softer suspension. To make it easier, my dealer jokingly called them the old mans sled. The zr was a lot stiffer suspension,,, made for harder trail riding and ditch banging. With the newer sleds, its the same difference between the sabercat and the firecat. The motor out of my f7 would be a direct swap with someone with a sabercat 700.
So the parts he has will fit,,, If you do decide to get them, I would look into new bearings and all while you are in there that far,,, new pistons and rings.
I am one of the guys that like the stock pistons over the weisco. Weisco is a good company and all, so I am not putting them down,,, just personal preference. You can go to www.brownleisureworld.com or www.arcticcat.com and both sites have entire breakdowns of your motor. As far as torque specs and all, I have them and can email them to you at any time. A manual would definetly be a plus and you can generally pick them up off ebay very reasonable,,,,
Let us know if you go with the parts and the rebuild, there are plenty of us here that can walk you right through the job,,, good luck
Brian

the 00 carb engine 600s(Millenium include are also diferent btw they are known as "B" series 5 more HP then the 98-99 600 as well as the 00 EFI 600

Everyone on this site is awsome (so far) I'm from many car boards, lots of not so nice people there.

Puree can you send the manual over so I can get a head start reading it? e-mail address should be in my profile.

I was thinking about new bearings while I was at it. Is it a hard job? Will I need special tools?

What I'll do is get all the stuff and get pictures of it and the damage, then get you guys to decide if the case is any good etc. Then I'll do the final deciding if its rebuild time, or scrounging time.

I like weisco pistons, I know a few guys running them in thier cars, but I've seen a few bad things about them in sleds. Somthing about having to warm up properly or else bad things will happen. The guy with the ZR has a set of stock used pistons "updated" ones.

Thanks so much guys

Jordan

I dont have the manual, just the torque specs and all. I can send you a copy of them if youd like,,,, the manual is something you would have to pick up off ebay,,, you should be able to get one pretty cheap there.

Check ebay for a manual

I got a CD manual for $8ca last summer

Its a God sent IMO

Picked up the engine today. Picking up the sled on Wed.
I was going to snap a few shots of the damage for you guys, but my camera batteries died.

I'll keep an eye on ebay for a manual. Found one for a 99. I'll keep waiting.

Jordan

Here are the torque patterns for most cat sleds,,,, hope this helps you out

the second picture would be the torque specs for most cat sleds,,,, now you should be ready to start digging in,,,, good luck
Brian

Awsome thanks!

I got all the stuff last week. I found a bottom end and new jug. I'm going to check over the bottom end when the engine shows up tommorow, then put in the old pistons and new rings, hone the cylinder very lightly. Hopfully this weekend I can bolt the engine back in. Then get it all set up for the first snowfall (I can smell it already).

Having a hard time finding a manual online though, specially since I want to do this this weekend. I'll give the dealer a call tommorow and see if they can order one in.

Also, my head in the one cylinder is pretty pitted from the damage. It looks like I could scotchpad it most of it out. Bad to run a damaged head like this? Should I be looking for a good shape one?

I also need to find a clutch alignment tool I guess. More research is needed on my part.

Jordan

I too greatly appreciate it!

Thanks Brian!

Some questions.

Lubrication while assembling engine? What do you use?

Figured out why the old engine died. Looks like it detonated pretty bad in one cylinder. Probably killed the bearing. Piston is destroyed, head is pretty pitted, but I'm going to run it for now.

How does the clutch attach to the engine? I havn't looked closely at it, but I think somthing is missing.

Can I syncronize the carbs and oil injection myself somehow? Or do I really need to take it to the dealer?

Ah the big question.... DO THE RINGS NEED TO BE GAPPED? I'm thinking no, they don't look like they were/are to be gapped.

I've got new pistons and bearings on the new engine, lightly honed teh cylinders walls. Saturday I pick up my gaskets and hopfully finish assembly, bring it home from work and throw it in the sled.

THanks

Jordan

Got the engine assembled today.

Found why that one cylinder was destroyed. Air intake boot was cracked and had a nice split in its seal. Other one is close.

Anyone have two of them? I don't want to pay 90 dollars each at the dealer.

Thanks

Jordan

Engine now sitting in the sled, wiring hooked up for the most part, fuel hooked up for the most part. Clip for oil pump isn't going as tight as I hoped it would.

Need clutch alignment tool, the install the clutch, finish bolting down mounts, and find some intake boots! Then I guess I'm firing it up for its first time. Hope I did everything well enough.

Jordan

I have 3 for a 97 zrt. But I am not sure if they fit or not. If they do, you can have them (you pay shipping). They are not in GREAT shape, but they will get you through this year with no worries. Take a look at either arcitccat.com or brownsleisureworld.com and see if the part numbers are the same. I doubt they are, but its worth the look. Good luck
Brian

Not the same. That sucks. When I get some more money into Paypal, I'll put up a wanted thread.

Thanks for the offer though!

Jordan

There are a couple of Cat salvage places in Manitoba. The one I have dealt with before is in Tyndall. His name is Perry and his number is 482-5044.

The other guy I've seen ads for in the paper and in the buy and sell but I have never used him.

Kevin

Got the engine assembled today.

Found why that one cylinder was destroyed. Air intake boot was cracked and had a nice split in its seal. Other one is close.

Anyone have two of them? I don't want to pay 90 dollars each at the dealer.

Thanks

Jordan
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Kimpex $25each

I bought some last year

Just checked them over yesterday when clean the carb and checking out the reeds and they are in :thumbsup: shape :)

Thanks Freezer, I'm doing a search right now for some.

And Thanks Kodi, I'll give him a call and see what he has later today.

Jordan

http://www.kpx-kimpex.com/catalogs/snow-enca/546.jpg
Are those them?

Picture doesn't look right, but probably just a different sleds.


EDIT: Just saw the part number there.... Great thanks!
EDIT 2: Since it looks like they only sell to thier dealer network, where did you end up getting yours? Or do they all sort of sell at the same price?


LMK
Thanks,

Jordan

any dealer that sell Kimpex parts

I went to Royal Distributing here in Sudbury but I could have went to any dealer and got them

Ya they look diferent from the pic above

IT RUNS!

I went out to a ditch last night and put 8 miles on it back and forth.

The bad news is it runs as if the stator is on its way out.

I'm going to check all connections, and disconnect the killswitch and see what happens.

But first

My key doesn't work, at all. Any common problems with them?

Thanks

Jordan