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Old 12-19-2009, 09:14 AM   #1
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Sled: '96 ZRT 600
10-11 Mileage:
09-10 Mileage: 185 so far
08-09 Mileage: 75
07-08 Mileage: 150
06-07 Mileage: 25
ATV: Depends who lets me borrow theirs
Just installed a KOSO digital water temp gauge on my 96 zrt 600. i wanted to keep the stock warning light just in case. Here is how i did it. feel free to comment.

[attachment=142289:2009_002.jpg]
First drain the coolant to below the water manifold, then remove the clutch side elbow that connects to the head.
[attachment=142290:2009_007.jpg]
Notice the flat spot in the casting, that is where the sensor will get mounted. drill a 21/64" hole thru and tap for pipe threads. in my case it was 1/8" NPT. not sure if a bigger sensor will fit here so keep that in mind. the tap was around $6 at my local hardware store. Make sure you go slow and back the tap out every turn or so to clean the aluminum chips out. also be sure to use cutting fluid or at least WD-40 on the tap.
[attachment=142291:2009_011.jpg]
Next screw the sensor in with a wrap or two of teflon tape.
[attachment=142292:2009_014.jpg]
Then you can re-install the elbow back on the engine. Make sure you get all of the shavings out first!
Fill 'er back up with coolant and run the sensor wires to your gauge. mine came with snap together connectors but of course there wasn't enough wire to make it under the engine and up the hood so i had to extend it with some 16ga stranded wire. if you have to do that make sure make sure you solder and shrinkwrap all the connections or it wont last very long. also be sure to route the wires away from any moving parts or exhaust pipes. i just zip tied it to the existing wire harness going up to the stock gauges.
[attachment=142293:2009_016.jpg]
there it is, i can keep an eye on the engine temp and still have the idiot light incase i dont notice the gauge.
Note: i didn't get the backlight hooked up yet because im pretty sure i need a rectifier to get DC Voltage. that will happen soon hopefully.
Any input is welcome!
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How to Install Coolant Temp Gauge-2009_002.jpg   How to Install Coolant Temp Gauge-2009_007.jpg   How to Install Coolant Temp Gauge-2009_011.jpg   How to Install Coolant Temp Gauge-2009_014.jpg   How to Install Coolant Temp Gauge-2009_016.jpg  

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Old 12-19-2009, 09:37 AM   #2
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Sled: 2002 zr 800 efi
10-11 Mileage: 200
09-10 Mileage: 500
08-09 Mileage: 500
07-08 Mileage: 500
ATV: 2004 Yamaha YFZ450
I also installed a koso digital water temp gauge on my 2002 zr 800 efi. I'll attach the pictures from my other thread from a week or 2 ago. My gauge is a little different than yours but it came with all the same hookups. I also didn't have enough wire and had to splice in and solder... I also wired my power to the fuel pump harness on my sled because that is DC power. I just hooked into the temp sensor that the ecu uses for the engine to save a little time on my installation also. Looks good by the way.

Chuck
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How to Install Coolant Temp Gauge-dsc01147.jpg   How to Install Coolant Temp Gauge-dsc01148.jpg  
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Old 12-19-2009, 09:43 AM   #3
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Sled: '96 ZRT 600
10-11 Mileage:
09-10 Mileage: 185 so far
08-09 Mileage: 75
07-08 Mileage: 150
06-07 Mileage: 25
ATV: Depends who lets me borrow theirs
I wish i had 12v dc somewhere on the sled like with an EFI model! oh well, im a sucker for more work anyway! i have to admit i like your gauge better, chuck. looks like it would be easier to read when riding. my first choice was a stock arctic cat gauge but the shop couldnt find one so they ordered this one.
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Old 12-19-2009, 10:55 AM   #4
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Sled: 2002 zr 800 efi
10-11 Mileage: 200
09-10 Mileage: 500
08-09 Mileage: 500
07-08 Mileage: 500
ATV: 2004 Yamaha YFZ450
I was going to get the stock gauge but for another $5 I could have that one so I opted on that one. If I had to do it again I would probably get the stock gauge due to ease of install though. I know the motor for the powervalves runs off of DC also but I'm not sure if your sled has them??? I also had to run another set of wires to the fuel pump on mine though... so thats 4 wires I had to run, almost 10 ft each!! its amazing how far it ended up being.

Chuck
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Old 12-19-2009, 11:26 AM   #5
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Sled: '96 ZRT 600
10-11 Mileage:
09-10 Mileage: 185 so far
08-09 Mileage: 75
07-08 Mileage: 150
06-07 Mileage: 25
ATV: Depends who lets me borrow theirs
No powervalves on mine. if the backlight is and led then it would work on ac, just wouldnt be as bright, right?? i dont want to try it and cook the thing though! if anyone knows where i can get a rectifier let me know!
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Old 02-14-2011, 09:01 PM   #6
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ok i know this is very old but i just wanted to say that all the lights on your sled are dc power same withe the hand warmes and stuff so its not had to fine power for a back light since you can just spice into the same back lights your gauges use
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Old 02-15-2011, 07:17 AM   #7
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 Quote: Originally Posted by 1996zrt View Post
ok i know this is very old but i just wanted to say that all the lights on your sled are dc power same withe the hand warmes and stuff so its not had to fine power for a back light since you can just spice into the same back lights your gauges use
These sleds actually run AC voltage to the lights. Electric gauges require DC voltage. The back light may work off AC, but powering the gauge itself is really the challenge.
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Old 02-15-2011, 06:08 PM   #8
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what dose the stock tack run off of?
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Old 02-15-2011, 07:14 PM   #9
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 Quote: Originally Posted by 1996zrt View Post
what dose the stock tack run off of?
It runs directly off the frequency of the AC voltage being produced by the lighting coil.

There are exceptions on 97 and 98 pantera and ext 580 EFI's because they use 3 phase stators and those sleds have DC systems.
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Old 02-16-2011, 08:49 PM   #10
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ok so how hard is it to put KOSO digital water temp gauge like chuck1221 has on his? and do you know about a 98 polars indy ultra 680
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