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howdy,  i was wondering if anybody has any advice about rebuilding a zrt 800 motor.  i have to do it from the botom to the top,  bad crank(getting it redone)  then up,  one bad piston,  scuffed jug(will be all right).  i have the service manual but was looking for any tricks or points of interest. can a person use the old base gaskets if they look fine/  THANKS
 

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For the cost get a new gasket.

Hopefully you sent the crank out to a reputable repair shop, you will need to have it trued up once the new rod and bearing is put in, also you may want to spend the extra money while you have it out and get it welded as well.

If the cylinder is not gauged and simply and get be rehoned it is pretty painles to do yourself.  If is needs to be bored or resleeved you need to look at many more things, pistons ect.

Did you spin a crank bearing as well or simply a rod?  Make sure all the alignment pins are accounted for and none snapped off.

Good Luck.

I-Cat
 

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Don't re-sleeve your cylinder it only runs into problems.  For some reason when you re=sleeve it there becomes hot spots in that cylinder.  Any how it doesn't sound like your cylinder needs it.  But if it does take it to a shop and they weld in the hole and re-nikasil.  I just did my Dad's cougar and we got a re-placement cylinder from Adrian Bardard.  Your dealer or machine shop should know who they are.
 
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