Taking ZX parts to REV ???????????

[AkHockey10]

..Alright, been thinking about this for a while now and since snow is around the corner (at least i think)...im getting more serious about this. Ready?

I found an 05 Summit 800 151" chassis. Comes with coolers, bulkhead, and i think the steering post and all the chassis stuff, lol. Not to sure about motor plates though. I am wondering how hard it would be to take my 02 800 motor and stick it in that 05 chassis, along with all the clutches, oil tank and all that? will it work? Im already in the hunt for REV in the fall but, wondering if this would be the cheaper route to go.. yes, i know i will need to buy some stuff as some of the 02 parts will not fit. figured that. Im i wasting my time?

BTW: my 02 800 has RER.

 

[Adrenaline Revolution]

I'm no expert but a buddy of mine did exacly what you are talking about with his ZX mod motor and clutches into a REV. (Not sure about the jackshaft and such though.)

obviously you'll need a new pipe and rev motor mounts but the rest was an exact fit to the best of my memory.

You'll need most of the wire bundle and teather from the ZX too.
Not sure about the oil tank but if you get into a Microfische for DOO you can start comparing part numbers from one model to the other.

Here's the one I use....

http://http://www.motoplex.net/pages/parts/viewbrands/6/default.aspx

Try PM ing summit800 and ask him for some advice.
He's a great source of info and a good guy to boot!

I'll give him a call for you and ask him to respond to your post.
He doesn't spend a lot of time on the 4M in the summer months but I'm sure he'd be willing to give you some help.

 

[AkHockey10]

Yeah, that would be cool! thanks, man!

 

[Adrenaline Revolution]

I just talked to him and so far, I've given you the right info !

He told me to give you his home phone number so you can call him this evening after work and he'll give you the complete low down!

I'll PM that to you now.

Sounds like a fun project.

BTW...Unless you have the REV clutch and electronics you won't have reverse but...It's still gonna have tons better ride and climbing ability.!

 

[Summitstef]

It will work.

I did this whole procedure. I had a friend do the motor swap. You will definately need a rev motor plate. One major thing to look out for is the way you mount your ignition coil. Be sure to use locking nuts on the bolts. Other wise your twin will turn into a one lunger. Also try to get an airbox that will fit, and do not use pods what ever you do. When you extend your wires of the wiring harness, get the uninsulated butt splices and then put a tube of heat shrink over the connections rather than electrical tape. This provide no water getting into the connections. If you update your DPM rail, be sure it is calibrated before you use it( annoying as hell!!!) Good luck!

 

[AkHockey10]

excellent!

so, doing the whole engine swap and what not.. is it actually a whole lot of work isnt it?

 

[hymark860]

its not a whole lot of work you just need to know what works and don't. Does the 05 have the MPEM and wiring harness in it? If not use the harness from your 02. I stuffed a complete 01 motor and harness into a Rev chassis.

You will need a Rev pipe, ypipe, and can, and motor plate. The oil bottle is also different. Rev reeds also have a slightly different angle. The zx reeds will work if you run pods. I have run pods for the last 4 yrs with no problems.

If you buy a air box. Get one off the 07 R motor. It flows more.

 

[AkHockey10]

Would it be possible to use my front HPG shocks? I have them set up the way i like and would be nice if i could still use them. I thinking that i would need REV a-arms, correct? how about the drive train?


Thanks for the help guys!!!!

 

[hymark860]

Front shocks and all drivetrain will work. The jackshaft needs the spacer changed behind the bearing to work on Rev.

 

[Heavysledz]

Check the eye-to-eye length of your shocks as the REV shocks are typically longer than the ZX Summits.

 

[Alberta Boy]

Check the eye-to-eye length of your shocks as the REV shocks are typically longer than the ZX Summits.

You are right... ZX are 17" eye to eye and I believe that the REV ones are 18" or so. When I went to order front shocks for my '03 ZX summit, I was asked what length of shocks I had as there were 2 lengths listed for '03 (REV mis season release of the REV Summit)

 

[MARV1]

Andrew, is this the complete roller on craigslist? Saw that too and was thinking of sticking my dad's 700 engine in it.

 

[hymark860]

I run 16.5 c to c on my front shocks. The summit shocks are 17" c to c and the MXZ s are 18. I would stay away from the 18 unless you have the wide front end. If you have summit a arms the front will sit too high with 18".

some of the earlier revs might have 18 but the last few years are all 17 now.

 

[AkHockey10]

Good to know!

hymark, thanks for the reply!

 

[AkHockey10]

I am also thinking that i will not be able to use my 02 rear skid, correct? Would it be possible to modify it some, so that i can use it?

 

[hymark860]

Skid should work fine. The front tq arm is the same as the 03.5 summit. Your mounting point might be slightly different. The 04 and newer tq arms are about a 1" longer. You can get a takeoff and bolt it in if you wanted.

You'll want the distances between the mounting points the same from one sled to the other.

 

[Summitstef]

Rear skid use

Your skid will work. when I threw the one into the REv from The ZX, I had to get a diffrent front arm for the skid and had to drill new holes in the drop brackets.

 

[snowcross338]

Rear skid is close to the same, if you drill holes in the rails you can move them to the rev locations, a little differant. I had bought 07' rails for a 01' summit I had and drilled holes because the two sizzors were in the wrong location. Track, skid, motor with differant plate and jack shaft, and it bolts in. Best of luck buddy! It is supposed to snow here in the high country Friday night!!!! Yippy!!! Early season? Can't wait till my shoulder is ready for riding! Had surgery July first and have 3 months of recovery/therapy. So I've been using this time to tear down, rebuild my motor and shave the head.

 

[AkHockey10]

Cool, thanks, Joe!

hope that shoulder heals before its time to ride!

~~~

'nother question.. For people who have done a project like this, did you take out the spacer in the jack shaft? howd that turn out?