I have a serious itch right now to start a LT500 project.
I would like as much good info as I can get in regards to best year to look for/avoid, fair price to pay, motor builders to avoid, common problems with the Zilla and fixes for those.

My intentioin is to build a hill shooter, using the OE frame if possible, run alcohol, +swingarm, ect., ect. Any set-up suggestions (carb/pipe?)

Been to Mr Dune's Zilla project page and got a semi going, any other info would be much appreciated.

 

Well, I just decided to start building a Zilla to,I found a frame, a arms, axle, tires and wheels, and shocks, and misc. parts for $400. From what I am told the 87 Zilla's were the bad years because of the head studs and something else, but I can't remember, I think it was a arms that changed? I don't really know about the engine builders though. Good luck.

 

The 87's had a square-tubed upper A-arms, a 6-stud head design, and a larger reed cage. 88 and up have 7 stud heads, round tubed A-arms, and a smaller reed cage. If your building a hill shooter, you'd probably want an O-ringed cool head, so the head gasket wouldn't be a prob, the A-arms wouldn't make much of a diff, but there are more aftermarket reedcages for the 88 and up jugs, and the most popular carb/pipe set-up seems to be a Paul Turner pipe and a Kiehin 39mm PWK(at least I think its the PWK)

 

I have the 87, and as of yet I have not had major problems, but it is true about the 6-stud head, go for 88 or above. On the O-ring head, remember that the original gasket had specific holes for cooling, so when you use an O-ring I beleive you need to have windows cut into the piston to get the same cooling.

 

I can't speak for zoo, buy with my o-ring head I did not have any "windows" cut in my piston. I own a 1987 zilla and had the stock head o-ringed rather than buy a cool head.

AZ400L, stay away from Jerry Hall motors. They are located here in town and the "scary Jerry" reputation he has lives up to it. My motor was a complete grenade and I ended up redoing everything.

I use a +2 Laeger swingarm with a 2+2 Durablue axle. I have a Kehin PJ 38 carb and it is a pain in the neck. It seems like week to week I am changing needles, pilots and mains trying to get the thing dialed in right. I would like to run alcohol in it when I go to the dunes but don't know enough about it. Do we have any alcohol experts in here (and I don't mean beer drinking because we are all experts on that)?

 

Thanks for the update on the info LT5001987, the info I sputtered out was what I was told and a seperate article I read. I try to be careful not to state things as fact, when I'm not sure or when it comes from a not-so reliable source. Thanks for setting it straight.

Have you had any problems since you've O-ringed the head?

 

Zoo

Yes, I have had problems, but none of them related to the o-ring head. This is a much better solution than the stock head gasket. Some folks have had good luck with copper head gaskets. May want to try that.

 

I was actually thinking about going with a powerhead O-ringed.

I can actually say that even with the stock head gasket I haven't had any problems, I am pretty consistant about re-torquing the head from time to time, and I've always rode my Zilla like it was stolen, (hard and fast).

 

I have recently discovered a sure cure for LT500R head sealing problems. I got rid of my cylinder and head completely and have yet to experience any of the aforementioned leaks. While I was at it, I chucked my carburetor over the nearest fence for an additional weight savings. True, it isn't nearly as enjoyable having my bike towed behind a Yamaha Big Bear. However, the maintenance savings are unbelievable!

 

AZ400L, I notice you mentioned Mr. Dune's Zilla project. That is a very informative and enjoyable to read article (even though I don't agree with every aspect). One thing you will want to ignore is the engine builder he chose. Read the Tudor's Performance thread on Performance Mods and Mechanical for a good reason to stay clear of them. I never felt the need for a signature until I made the mistake of dealing with these people. Tudor's is also a sponsor of "Quadzillathon" which you may have run across while searching the net. It is too bad that THE premier Quadzilla event is mared by this outfit.