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Old 03-05-2007, 11:07 PM   #1
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Hi guys I have an update to my project for you today. My sled- 6/1992 Arctic Cat 550 Special now with a 580. I blew my 550, so I found a new engine from a 1995 arctic cat ZR 580 with everything on it ( I originally thought it was from a 1994 zr 580 but the red spring and 49.5 Gram weights and the 3 degree carb slides makes it a 95. OK first things first I took it to our local custom shop to complete my engine upgrade which should have only been a carburetor cleaning and to make sure the bog was gone- that turned into cone air filters and 3.5 hours of labor….Cool right well no I got a call saying its taking up to much time and that they couldn’t fix the problem I took it there for-Bogging. Now I have the sled back with these symptoms. Fires right up, idles- if I slowly hit the gas, I can make it to about 20 MPH then she shifts into a like second gear (takes about 300-400 RPM away) and the result is slowness. This thing seems to get WAY TO MUCH GAS-if it’s warm I can’t make it up hills or cross roads when I stop. I have floor the thing to go anywhere and maintaining a steady speed doesn’t work at all I have to floor it to say moving pretty much. OK to RECAP I have a 1992 EXT Special 550 with a 95 ZR 580 motor- I am running stock 550 pipe,( is this bad? If yes then i'm looking for one) I am running stock 550 Fuel Pump-I am running a red spring for primary, and yellow for secondary- The 580 came with huge carbs so that should not be a problem, (I told the repair shop at the time the 580 was from a 94 zr so that’s what parts they put into the carb rebuild). FYI If I floor this thing she FLYS I can pop some nice wheelies until the thing “shifts”.

So my questions are,
1. Why does this sled shift into another “gear” at about 20 MPH
2. Do the carbs need 1995 parts vrs 1994?
3. Would the 550 exhaust make this bogging problem?
4. Has anyone done this conversion before?

THANK YOU ALL SO MUCH FOR YOUR HELP!!! One of my repair shops as you can see wants nothing to do with this!
Attached Thumbnails
1992 EXT 550 - 580 Upgrade!! HELP ME TUNE IT PLEASE!-new_years_mudding_001__small_.jpg   1992 EXT 550 - 580 Upgrade!! HELP ME TUNE IT PLEASE!-new_years_mudding_089__small_.jpg   1992 EXT 550 - 580 Upgrade!! HELP ME TUNE IT PLEASE!-winter_time_086__small_.jpg   1992 EXT 550 - 580 Upgrade!! HELP ME TUNE IT PLEASE!-100_5911__small_.jpg  
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Old 03-06-2007, 12:05 PM   #2
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i dont know if this was ever a problem on that engine, but it sounds like it could be a stator if everything else is fine. I know the 97 580 stators all had to be rebuilt/replaced. One I had would only sometimes cut out at WOT and it would drop 300-500 RPM and then run there. The 2nd I had, finally got to the point of not even starting.
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Old 03-07-2007, 05:56 PM   #3
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Sled: 2000 ZR 600 Carb
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Good to see that you got the sled on it's feet again. Are you using the clutch that came off your 550? If not that could probably be your problem? In my 93 580 Z (same style sled as yours) I have a yellow/Green primary spring. Is the secondary spring the same one you had or did you change that out too? I'd put your 550 primary clutch on it and I bet your problems would go away.

Also that exhaust pipe looks identical to the one on my 580 from what I can see in the pic so I think you should be ok there.

Hope this helps.
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Old 03-08-2007, 12:36 AM   #4
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Sled: 2007 F6 Snow Pro
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07-08 Mileage: 1,700
06-07 Mileage: 760
Here is what i have for clutch and driven clucth

Primary RED spring 49.5 G
Seconday YELLOW with a 58 Degree Bracket - I thought i should put everthing stock for the 1995 ZR 580.... Maybe I need to copy the 93 580 Z instead? Thanks Guys!! - i'm glad i got her running again to! I love the way it looks and drives!!! Later, Donnie
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Old 03-08-2007, 04:01 PM   #5
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The 94 580 ZR had 40mm carbs if I remember right. They were a bugger to tune.
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Old 03-08-2007, 05:38 PM   #6
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I wouldn't use the clutch spec's from the 95' 580 as the chaincase gearing would be different and I bet that's why your having your problems. set your clutch's up just the way it was with the 550 and it should be good to go.
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Old 03-08-2007, 09:10 PM   #7
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OK after work friday tomorrow i will try to find a clutch puller and get that 580's clutch off and put my 550's back on, like you guys are saying i think THINK its in the clutch, i know i have a bogging problem, but she is "shifting" and of course the engnie is working duble time at a lower RPM so i would loose power. And yes it is all setup for the 95 ZR i even have the 95 ZR Carbs on my 92.... I hope they can tune to the 550 92 muffler - this is one HUGE can of worms i opened, but it was fun and I believe with your guys's help will get er done! Ill shoot up some more pictures for you guys later.
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Old 03-08-2007, 11:19 PM   #8
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Here is a pic of my 93 580 exhaust, I guess you could see if the pipe is actually different or not. Also my 580 is running the 38mm carbs. Let us know what changes you see when you get the 550 clutch's on.

[attachment=65853:HPIM0222.JPG]
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1992 EXT 550 - 580 Upgrade!! HELP ME TUNE IT PLEASE!-hpim0222.jpg  
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Old 03-09-2007, 06:29 PM   #9
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Sled: 1996 zr 580
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2007 Mileage: alot
you say it has a 58 degree bracket.. well that might be the problem stock zr 580 has a 53 and the ext has a 49
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Old 03-09-2007, 08:09 PM   #10
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07-08 Mileage: 1,700
06-07 Mileage: 760
Ok I got a little update here Its raining outside so I just called it a night for now, but after dann told me about the bracket in the driven clutch i did some research. I made a type'o in one of my last posts i have a 53 Degree bracket on right now NOT 58 but dann is right i should have a 49 degree bracket on. SO the only reason I haven't swapped clutches is due to no clutch puller but i plan on purchasing one. Oh and Panther500F i put a picture of my engine up your muffler looks JUST like mine, I don't think thats the issue anymore? Thank you all again for your help,
Donnie
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1992 EXT 550 - 580 Upgrade!! HELP ME TUNE IT PLEASE!-winter_time_087__large_.jpg  
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