Rotax 617 into my 94' ZR-440

[Brute71]

Bought a ZR-440 chassis with some sno-pro Fox shocks on it a while back and had them all redoone, now I'm on to the engine. I was going to try and find an arctic cat LC 440 to toss in but I found a deal too hard to pass up! $50 and a 10min drive later I picked up a 1991 Ski-Doo Formula Mach 1 with a good engine and everything there! The 440 was missing the coolant tank and what not so that stuff will be pulled from the mach 1 and placed in the 440's chassis. Here's where I'm at currently:

Old engine out:

New engine to be put in, going through it right now:

That oil tank sits in there a little too well...

Working on pulling out the wiring from the donor sled, then Im going to get that put into the 440. After that I will work on the gauge cluster so I have everything needed from the Mach 1 (tach, temp, oil level light, etc) on there and looking as it should.

Hoping to use this build as an experiment for some certain things to use in other projects!

 

[Longview]

I'd love to get a Sled.

I'll be staying tuned for this build.

 

[Brute71]

touch of progress, got the wiring harness free'd up on one end. Just need to trace some leads and mark them out then pull it free. Also got all the needed gauges pulled, the fuel pumps pulled, and the primer out (carbs use a primer instead of a choke).

Need to rock out a new engine mount plate so I can start measuring out how things will fit in to place. Gonna pull out the heat exchangers out of the Mach 1 and see if I can get them to work in the arctic cat, otherwise im going to need to do some work with coolant hoses and see if the 440's heat exchangers are enough for the Rotax.

 

[98blaster+4]

keep up the progress bud, and keep the pics flowing.

 

[Brute71]

Donor sled is nearly 100% gutted! Just need to drill around 50 rivets to get that heat exchanger out and then it will be time to tear down the ZR440, then it's time to put it all together

Copper enriched spaghetti anyone?!?!

Gonna start marking the leads out as well, might need to use the tail light wiring from the zr440 since that one has the contact switch at the handle to make the brake light work.

 

[Brute71]

Heat exchangers out! Now on to the putting it all in (yes, that is my Blaster in the background)

 

[Brute71]

Made a little progress last night. Pulled off the seat, tank, and rear heat exchanger. Still need to pull the drive shaft and front HE. So far it looks like the HE's off the mach 1 will drop right in after i make some holes for the front coolant tubes and rivets.

That is the 440's original rear heat exchanger sitting on the 600's.

 

[Brute71]

Ripped out the driveshaft last night and checked out how the new heat exchangers fit in the tunnel. Just gotta pull out the front HE then I can start getting the new ones in. After that I gotta finish up marking wires and make a new engine mount.

 

[98blaster+4]

good progress bud, gonna be a ripper!

 

[Brute71]

Got the heat exchangers almost 100% in tonight, 36/42 steel rivets in by hand. Gotta pick up some more since I ran out. Gotta rig up some way to mount the seat now, got an idea to accomplish that. Also gotta pull out the old chassis (or old engine) and get a ctc measurement for the clutches so I know what belt to get.

Now on to the wiring and mounting the oil and overflow tanks.

Holes drilled for the inlets:

Riveted in place (mostly):

Shot from the back (before I started throwing in the rivets):

Should be able to wrap this up pretty soon!

 

[Brute71]

Got the holes drilled for the fuel and temp gauges in the hood, need to do up an adapter for the rpm gauge. Might make an aluminum plate for the adapter and at to the cosmetics a bit. Need to grab myself some 1/8" aluminum plate in the morning so I can do up the seat mount as well. Now to come up with something for the oil tank and coolant overflow tank mounts and get cracking on the wiring.

Cluster right now, still has the old tach in there:

Clearance for the barbs from the tank, should work perfectly:

 

[Brute71]

Picked up some more aluminum this morning, expect some progress when I get off work

 

[NOVIS]

mixin a cat with a skidoo. probably never been done before haha! thats a cool build man. i wanna drop a big engine in my enticer and have a sleeper lol.

 

[Brute71]

Lol thanks man! This thing should be quite the sleeper itself when its done.

 

[Brute71]

Got the first mock up out of the way, simply put it'll fit. Engine will need to sit at an angle so those engine mounts will be a challenge to fab up, i will need to put in some level of adjustability to be more flexible with belts. I will probably want to angle the header so the pipe has a bit more room and so i can keep the engine down low. Carb also sits a little close to the steering stem but i can work with it.

 

[slickerthanyou]

Got the first mock up out of the way, simply put it'll fit. Engine will need to sit at an angle so those engine mounts will be a challenge to fab up, i will need to put in some level of adjustability to be more flexible with belts. I will probably want to angle the header so the pipe has a bit more room and so i can keep the engine down low. Carb also sits a little close to the steering stem but i can work with it.

Holy Projects! I have some experience with the heat exchangers for water treatment purposes, however not for a sled or doo! But they all work the same! Has to easily be one of the greatest projects going!

 

[Brute71]

Thanks slick! Still got quite a few man hours left to put into it, but it will wind up being one of the cheapest projects i have done! Lol

 

[Brute71]

Managed to rock out some fab work today in the heat! Got the front heat exchanger replacement piece done and mounted and the rear one fabbed and mounted. Should start becoming clear as to how I will mount up the seat soon! Also now can mount up my oil and coolant res tank up.

Gonna try and rock out the seat mount and the mounting of my oil/coolant tanks soon here. Gonna take the track off the donor sled as well, then I should be able to put my skid frame back in and finally concentrate on the engine mount!

 

[98blaster+4]

yeah, cool freakin porject! making damn speedy progress too so we all dont have to wait for more pics to drool over.

 

[Brute71]

Since i dont have to spend much money to make progress it helps move things along a little faster haha