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93 550 into 98 500 machine

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Apr 26, 2011
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1
3
I picked up a 98 ZL 500 a couple weeks back for 150 with what the kid said was a small problem. Well it turns out the crank seems to be split inside.

Up to current a friend of mine traded me a 1993 550 EXT for some work I did on his truck. The 550 EXT smokes like a chimney and seems to have an excessive amount of oil in the exhaust/everywhere.

My question for today is, can I swap the 93 550 into the 98 ZL machine? What will I need to do. Both machines are carbed with everything looking the same, but I need to know the clutches will match up.

As I'm sure you're all very well aware by the information in my post...I am very new to snowmobiles. My father had an old school cat a while back that we used to ice fishing, but other than that my knowledge is limited. Any help would be greatly appreciated on both getting the 550 runnin sweet and the swap thoughts.
 

Idcatman3

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Nov 26, 2007
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Idaho Falls, Idaho
You'll need to order a few parts, but it shouldn't be too bad. You'll need all the motor mounts for the 550 engine in an AWS V chassis. Those are:

0608-235
0708-114
0745-135

All your electronics will work, but if you don't swap your key and handlebars, the key and kill switch will work backwards.

You can likely use the clutches from the 500 on the 580. Power is similar, so the calibration will be close. If your primary on the 550 is in good shape, you can also just use it.

Your exhaust from the 550 might not fit quite right, but if you need one, you can get one from a '99+ 550, part number 0712-337.

Airbox should be close.

That's all I can think of off-hand.
 

Idcatman1

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Nov 26, 2007
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Ashton, Idaho
My son is right about it being a fairly easy swap. It sounds like your oil pump on the 550 may be pumping too much oil. There are alignment marks on the arm that is pulled by the throttle cable to tell you where it should be wide open.
 
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