1998 ZL 440 Liquid Mods-Any thoughts??????

[lcfcats]

Hi all, I have a very clean 1998 ZL 440 liquid. Its a great sled, only 2200 miles. It was the wife's, but she has decided she is more happy as a passenger on the back of our '02 Classic 600 Touring sled. So I get to ride the ZL if I go on a trip with the guys, etc.

My question is this... are there any tricks that anyone knows that would pull a few more ponies out of the ZL? (clutching, gearing, exhaust, etc) I know it was not a powerhouse to begin with, but anything would be a plus. (Don't tell me to sell it and buy something bigger, because it would be hard to find something this clean and with low miles again and I got a deal on it.)

I had a mechanic tell me to shave the heads down a little bit, clean up the jetting and monkey with the clutches. As far as I know the jets are stock, and I am guessing all hardware in the clutches are as well. Both clutches have the yellow springs. I have looked for exhaust cans and can't find any.
I am more concerned with bottom end power. Most of our riding is in Northern MN, WI and the UP.
Maybe I am SOL, but I thought I would ask here to see if anyone had any ideas.
Thanks again for the help!

 

[timmer72]

On the 1997 ZL 440 I had, the jetting was fairly fat...I dropped the mains 2 sizes and dropped the needles one clip.. That was good for most weather. The sub zero riding might be a little iffy. The mileage also improved doing that too. Most guys are going to keep 68 hp taped all day. With shaved heads though you will have to do some plug checking with the extra compression. Not sure who made them but I believe there used to be a twin pipe kit, maybe Black Magic or D&D perhaps.

 

[lcfcats]

Thanks Timmer72! Very helpful. I will do some research on the exhaust!

 

[mikedrh]

Buy a good clutch kit and leave the rest of it alone.

When the HP goes up the reliability has a way of going in the oppisite direction.

Shaving heads, porting, pipes, etc. will net minimum gains and maximum headaches on that engine.

 

[whitedust]

lcfcats all my buds in the past that had low hp & limited budget that wanted more hp introduced mods that were a PITA & if one thing wasn't breaking it was another & always on trips. Your buds will wait for you don't worry about it... maybe a clutch kit but reliable mods stop there for a trail sled. 440 is a very good trail spinner you will only get buried in the straights or on grades.

 

[lcfcats]

Thanks for the insights! Thats what I am thinking of doing. I want to keep the ride-ability of the machine.

 

[whitedust]

Thanks for the insights! Thats what I am thinking of doing. I want to keep the ride-ability of the machine.

Also becarful with jetting don't want to meltdown on cold days stock 440 built to scream on bottom & top but don't lean her out not worth the risk.....your buds will be happy to wait not so happy to tow you out of the UP for repairs or blown engine.

 

[lcfcats]

I have heard from more than one person(as well as above) that the jetting is rich and I should take it down two sizes. I'm thinking that might be too much. Would a guy be ok with going down one size? I just don't want to be that guy who is constantly changing jets.
I havent fiddled with carbs much, not that I can't learn. Had all EFI ZR's prior to this.

 

[fish633]

You can easily drop one jet size without any problem or gain for that fact.Sleds are jetted so rich from the factory its obnoxious.Factory sets then up to run and not melt from-40 to +40.I would feel confident dropping 2 jet sizes without looking at a plug or worrying about changin weather.
As far as other mods go,most people dont give enough thought to matching the components to desired results.example a pipe that is built to deliver power at xxxx rpm range yet have the cylinder ported for something else and clutched at even something different than that.factor in the chain case gearing and you have a can of worms.
Ignition timing is a factor in a two stroke,most people are scared to death of the stator plate.Yet it is the most important component of pipe dynamics.Therefore combustion will suffer leading up to a poorly running engine.
Using proper tuning techniques I would not have any trouble dropping more than 2 jet sizes or be suprised if optimal jetting was up to 4 sizes smaller. I would add that is when temp and humidity will become a concern.Generally speaking on an engine tuned to the fine edge, a change of 10deg would require some attention paid to your jets.
No 2 engines are the same or cylinders for that fact so what worked for someone else is pretty much irrelevant.I have had situations where one cylinder will tune different to another and they'er both on the same engine.
In closing you can find more hps on stock engine withuot any major work easily.

 

[lcfcats]

Appreciate the thoughts. I will likely just drop a jet size and do something with the clutches. We do run into occasional temp swings, and I don't want to worry about burning it up.

 

[whitedust]

Appreciate the thoughts. I will likely just drop a jet size and do something with the clutches. We do run into occasional temp swings, and I don't want to worry about burning it up.

Jetting 1 size down ok but still be carful -20F days. Clutch kit does not add HP just the way you use the hp ... to me 440s find on low end almost perfect twisty trail spinners but need help on top end.

 

[fastcat800]

Stock clutching on the little motors is spot on. I doubt you will find anyone who makes a clutch kit for it and for the price vs performance gains it would be a waste of money if you can find one. AC's 440 are always way too fat. I had a 96 440 ZR that was jetted down 5 sizes (running right on the edge at -20) and a 97 ZL 440 that was jetted down 2 sizes since the day I bought it at Haydays in '98. Stock it was so fat it didn't have enough power to drive it up on the tilt trailer on a warm day. Every carbed Cat I have owned was jetted down two sizes by the next day and run on regular gas including a ZRT800 and ZR800. That being said, I am going to tell you to sell it and buy another sled. The ZL is designed to ride and handle like your two up touring sled. It has mushy shocks and a low HP motor. Sell it and buy a Firecat and for $1000-$1500 more you can have a fantastic handling trail sled with decent power even if you only buy a 500.

 

[cooksend]

As others have said, Jetting on this sled is the key! It was at least 2 jet sizes fat from the factory!!! We would always recommend dropping 2 from day one and if you ride in temps around -20 check piston wash. The sled has a high engagement and high rev to get whatever they could out of this little motor. In my opinion a bit of jetting and a bit of clutch work is worth the time and money. If you are willing to put $1,000 in the sled, sell it for what you can and put that $1,000 into a bigger sled. Heck the ZR500's were over 100hp and really hauled the mail! The retail value between a 1997 ZL440 and a 1998 ZR 500 is only a few hundred bucks! For less than a grand you can upgrade and gain way more power than you will ever get out of the ZL and also get a better shock package to handle hot rod days with the boys!

 

[whitedust]

As others have said, Jetting on this sled is the key! It was at least 2 jet sizes fat from the factory!!! We would always recommend dropping 2 from day one and if you ride in temps around -20 check piston wash. The sled has a high engagement and high rev to get whatever they could out of this little motor. In my opinion a bit of jetting and a bit of clutch work is worth the time and money. If you are willing to put $1,000 in the sled, sell it for what you can and put that $1,000 into a bigger sled. Heck the ZR500's were over 100hp and really hauled the mail! The retail value between a 1997 ZL440 and a 1998 ZR 500 is only a few hundred bucks! For less than a grand you can upgrade and gain way more power than you will ever get out of the ZL and also get a better shock package to handle hot rod days with the boys!

X2 .....ZR500 was a hot little sled very light for the day if you like the ZL 440 the ZR500 will knock your socks off!

 

[warner]

i have a set of black magic twin pipes with stingers i will sell you for 120.00 bucks..they came off my 97 zr440

 

[Quardt5]

Icfcats,
I have just purchased this past weekend a very clean 1998 zl 440 not sure I want to mess with it as I obviously have not ridden it at all yet. I would be interested in what you do to yours and if it makes a difference.

 

[timmer72]

One thing to think about when it comes to performance on this machine is traction.... It has a very short lug track maybe only 3/4 or 7/8 inch lugs if I'm not mistaken. 72-96 one inch long trail studs would greatly help acceleration and braking. With those, a 6-8 inch carbide in the skis will help it turn well too. I prefer stud boy duece bars for the stock skis. Good traction can make up for less HP in the twisties....but not much on the lake.

 

[lcfcats]

Thanks for the advice guys. Will likely do something with clutches and take a look at the jets. I know what the ZRs will do, as I have had 3 600s and loved them. Had a Firecat, hated it and went back to a ZR. At this point, due to cash flow, different sled is not likely. I will do what I can to this sled and learn to love it regardless of the outcome.

Thanks for the offer Warner, but I do not believe the engines are the same.
I have 96 Studs in it Timmer72, and agree that traction is key!
I will post what I do with it and how it works out!

BTW, would a ZR 600 motor be an easy swap into that sled/would it make sense? More of a random thought than anything.


Thanks again for the advice!