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Old 11-11-2005, 12:06 AM   #1 (permalink)
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zr580 psi twin pipes, jetting ??

i want to get a set of psi twin pipes for a zr580, i am planning on putting them on a cougar 550. All the measurements are the same on the engines (exhaust ports inside and out, exhaust dump on chassis, ect.) so i am not worried about them bolting up, i am concerned with the clutching and jetting though.

the sled has a yellow/white primary spring in it and engages at 4500 rpm. It also has weights from a 99 zr500 (not sure of the weight). Is this close to what i need?

zr580 has 40mm carbs, 550 has 38mm carbs, i understand i need to go up in main jet size to account for the increased air flow, question is how many sizes?

any insight would be appriciated.
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Old 11-11-2005, 06:01 AM   #2 (permalink)
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I'm sorry, but my insight says you're wasting your money!! I truly don't want to sound like a d!ck, unless you have a sentimental attachment to that particular sled, why don't you save the money & put it towards a newer, more powerful sled??

I had a ZR580 last year that ran very well w/o mods (~95HP). What are you looking to get out of the 550?? Anyway, to answer your question, rule of thumb is +2 jet sizes for pipes. Read your plugs & adjust as needed.
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Old 11-11-2005, 12:08 PM   #3 (permalink)
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Thank you for answering my question and not just telling me i am a moron for moding my cougar. My stock pipe rusted through and the stock canister flange is basicly gone, I found a good deal on twin pipes so I figured why not. I am not looking for an incredible gain in Hp or torque, I just wanted to make sure I didn't burn things down!

And yes I do kind of have an attachment to this sled. I take pride in taking the road less traveled! I have upgraded to a 00' ZL skid frame and have plans to install AWS V. I love the reaction when people ask me, "What kind of sled is that?" and i say "Its a 95 cougar!"

Here is a picture of my sled, so you can see what I'm workin with!

http://www.snowmobileforum.com/showt...?threadid=8547
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Old 11-11-2005, 01:22 PM   #4 (permalink)
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Looks good!! Like the "Blacked Out' look.
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Old 11-15-2005, 05:17 PM   #5 (permalink)
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drop a zr 800 motor in 'er and then youll really confuse the crap out of everybody!

looks really good, you did a good job with the hood, most you see the paint is either original and faded or they just took the stickers off and spraed it without any prep
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Old 11-15-2005, 07:18 PM   #6 (permalink)
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Looks nice.....I love the night rider look.
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Old 11-15-2005, 08:27 PM   #7 (permalink)
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Well stock on the Cougar's was 50.5 grams and a ZR500 is 46.5 so I would think you would want around a 55 gram weight if not higher with the same yellow white spring or orange white primary. Jetting I would say 3 sizes up on the mains to be on the safe side. I have no idea on helix though but the yellow secondary spring should be fine if that's what you have.

I had a 97 Cougar and loved it but it had it's life ended short. That thing was fast....would keep up with my buddies 98 ZR500 (sled lenght), 97 XC600 (smoked it), 97 ZRT600 (even), 97 MXZ670 (sled lenght), 99 MXZ500 (smoked it), 99ZR600 (in the ball park but strongest off all above) in a straight line and just as good if not better in the trails (I know mostly rider).
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