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Discussion Starter · #1 ·
My buddy has a 98 ZR500, just purchased, the sled has 5000miles on it, and it has frame damage (new that when he bought it). The bulk head is cracked and took out the cooler in front of the track, along with the piece that holds the jack shaft and the rear torque stop. He wants to know, has anyone mounted or added an aux cooler somewhere else on the sled as it is too much money to fix, or should I say replace the entire frame, the motor only has 1000miles on it, it still runs strong, and everything else is mint. He took it to a local welding genius and was told the cracks are to far apart to be fixed. Would it have heating issues with only the tunnel rails as coolers? We were thinking of putting a small heater core out of a vehicle (he works in a parts store), in there somewhere but not to sure on placement. any thoughts or ideas would be great. He was told of people doing this to other CATS, so has it been done? Can it be done? What parts are needed?

One more thing my 99ZR700 had different gears in it and the bearing went bad, bottom of chain case, it took out the gears and chain so I put my stock gears and a new stock chain in. It doesn't have the snap it had and I can't remember what I had in there. What can I go for gears, don't need a lot of top end 85-90 max is fine. With the stock gears it could go to the "A" in cat on the speed o , no need to go that fast, With the after market gears it would pull the skis for a hundred yards or so, and would still show 95-100mph on the speed o , and now "wheelies" 10-15ft at best, but crazy top end again. Looking for bottom end, not top end, but want to keep my new chain. The shop that did the work closed up and didn't give back old parts.

Thanks DAVE
 

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for gearing look in performance/racing in the top is for gearing chart.

for the other not sure. but theres always a way
 

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Discussion Starter · #3 ·
Sure that gearing chart works great and all but, what I need to know is what gears work with stock chain then I guess I could play with different combo's.

Also back to the little 500, can you run just tunnel coolers or do we need that rad or a rad of some kind in there. I dunno I dunno

Thanks Dave
 

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Discussion Starter · #4 ·
Come on guys, someone has to know something... Throw something out there for me please.. Any ideas, anyone
 

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Strock gearing according to fiche at Alphaparts.com (or whatever it is) is 24/40 with a 72 pitch chain?? Thats some tall gear isn't it? geez...and would a 72 pitch even fit that? if you do what 3 jugs said and go with a 22 tooth top sprocket it will fit your chain and be geared down quite a bit.
 

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I run a 24/40 on my zr800 and I love it, only 1 tooth down from stock(24/39) which figures out mathmatically to about 3MPH slower than stock providing you can pull the gear to begin with and yes, it fits a 72 inch chain perfectly, nice and straight on both sides with very little adjustment from roller which is the most efficient. Gearing down 2 teeth on top figures to about 12 mph slower which is to much and chain would be supper sloppy needing alot of adjustment from roller.
 
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