New sleeves needed zr400->615cc?

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New sleeves needed zr400->615cc?

22 May 2022 19:21
#867532
I’m prepping for a wiseco 615 engine build for my zr550.  cylinder heads are few and far between. I’m thinking about buying a zr400 cylinder head from japan (there are many used ones available). Anybody know if I can bore the 400 jugs to 615cc without having to replace the sleeves? My understanding is that the zr400/zr550 engines are almost identical, other than the pistons and crankshaft. 
1990 Zephyr zr550 B1
Wiseco 615cc kit
zx550 cams
SPII ignition system
Kerker stainless steel race exhaust with 1.5" competition baffle
K&N Air Filter...

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Re: New sleeves needed zr400->615cc?

23 May 2022 04:42
#867550
I think that the Zephyr400 used smaller sleeves to keep the wall thickness as such it would dissipate heat properly. So I believe that to bore them to 550 or 615, the sleeves are removed, the block bored and the 550 sleeves are installed. 
There is a zr550 cyl block on eBay right now, that might work. 

Here is a Japanese blog/post that I think illustrates the 400 to 550 process. (Google translate will help) 
erkkiyonaga.blog62.fc2.com/blog-entry-138.html
1990 zr550
kz750e
650/750 6-speed Transmission Swap


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  • Stereordinary
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Re: New sleeves needed zr400->615cc?

23 May 2022 08:59
#867578
Does this answer your question?

 

Haha, just kidding. 

But I am curious why you would need another jug, instead of just using the one that’s already in your bike? 

By the way, nice to see you both. 
A breeze from the west.
‘90 ZR550 Zephyr

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Re: New sleeves needed zr400->615cc?

23 May 2022 19:10
#867614
wrote:
I think that the Zephyr400 used smaller sleeves to keep the wall thickness as such it would dissipate heat properly. So I believe that to bore them to 550 or 615, the sleeves are removed, the block bored and the 550 sleeves are installed. 
There is a zr550 cyl block on eBay right now, that might work. 

Here is a Japanese blog/post that I think illustrates the 400 to 550 process. (Google translate will help) 
erkkiyonaga.blog62.fc2.com/blog-entry-138.html



 
Ah. I think you’re right. Good to know, and good Japanese website sleuthing. Thanks!
1990 Zephyr zr550 B1
Wiseco 615cc kit
zx550 cams
SPII ignition system
Kerker stainless steel race exhaust with 1.5" competition baffle
K&N Air Filter...

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Re: New sleeves needed zr400->615cc?

23 May 2022 19:20
#867615
wrote:
Does this answer your question?

 

Haha, just kidding. 

But I am curious why you would need another jug, instead of just using the one that’s already in your bike? 
That’s a sweet bike. 
I’m planning to build the engine over time and want to keep riding while I’m doing it, hence ordering extra parts rather than modifying my current head.
1990 Zephyr zr550 B1
Wiseco 615cc kit
zx550 cams
SPII ignition system
Kerker stainless steel race exhaust with 1.5" competition baffle
K&N Air Filter...
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Re: New sleeves needed zr400->615cc?

24 May 2022 08:23
#867631
Ah, makes sense. Figured that had to be why. 

I wanna do the same thing, but instead of a jug I want to find a whole bike, lol. 
A breeze from the west.
‘90 ZR550 Zephyr

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Re: New sleeves needed zr400->615cc?

24 May 2022 17:18
#867644
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Ah, makes sense. Figured that had to be why. 

I wanna do the same thing, but instead of a jug I want to find a whole bike, lol. 
 
I actually did that - bought a parts bike thinking I would modify that engine, but the bike is in such good shape (only 10K miles and unmolested) I think I'll just keep it stock as a spare. 

 
1990 Zephyr zr550 B1
Wiseco 615cc kit
zx550 cams
SPII ignition system
Kerker stainless steel race exhaust with 1.5" competition baffle
K&N Air Filter...

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Re: New sleeves needed zr400->615cc?

24 May 2022 17:48
#867645
Nice! I'd probably do the same thing. My current (one and only) bike (550 Zephyr) is mostly original, but after the accident I was in last year it's now a rebuilt title, so I kind of feel free to modify it tastefully as I see fit. So if I can get another bike to ride while doing the big bore kit I won't hesitate. 
A breeze from the west.
‘90 ZR550 Zephyr

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Re: New sleeves needed zr400->615cc?

25 May 2022 15:46
#867684
I also found that getting spares for a zr550 was really difficult, so I bought a parts bike and upgraded my kz750 with some of it and tidied up my zr550 with the rest. I also ended up with a complete motor that only has a little over 3,000 miles on it. My spare bike parts take up more room than my actual bikes. 
1990 zr550
kz750e
650/750 6-speed Transmission Swap


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