Zxi 900 to 1100 conversion

[Ttrm007]

Blown motor in my ZXI 900. Thinking of putting an 1100 rebuilt in it since I have to spend the money. Sounds like carbs, jetpump need changes.

How about exhaust? Anything else?

[steve45]

The exhaust manifold is different, as is the ignition ignitor. The 1100 had the automatic trim system. I think you can do without that.

[Ttrm007]

Sounds like a lot more involved

The exhaust manifold is different, as is the ignition ignitor. The 1100 had the automatic trim system. I think you can do without that.

So now it is exhaust, carbs, pump, ignition.... maybe not worth it, but I also see these parts are pretty available on Ebay and not too much money.

What is the 'automatic trim system'? Mine has power trim (up down control at the left control).

Tom

[cocacolaxyz]

KATS
I went through a lot of trouble making my ZXI 100% including this trim system. The standard is all I am using

[steve45]

The 1100 ZXis had the Kawasaki Automatic Trim System (KATS). You push a button and it automatically sets full down trim to give better acceleration from a standing start. After a certain (speed, or RPM, or time--I don't remember) the trim automatically moves to the neutral position. It was supposed to help you win drag races or something, but didn't do much in my opinion.

[Ttrm007]

Part Numbers I've Gathered

Comparing 1100 and 900 on Partzilla I came up with this. I'm worried about accuracy because the carb assembly numbers are the same but I KNOW the 1100 has the accelerator pumps and the pictures on Partzilla even show the pumps? According to this the exhaust, igniter, and even carb assembly are the same but I know I need Carbs with Accelerator pumps and new jetpump (bigger diameter).

Part Desc	900 Part #	1100 Part #
Exhaust Elbow	18049	18049
Header Pipe	59081 / A	59081
Muffler	18180	18180
Water Box	49070	49070/A
Igniter	21119/A	21119/A
Generator Stator	21003	21003
Carburators	15003	15003

[Ttrm007]

The 1100 ZXis had the Kawasaki Automatic Trim System (KATS). You push a button and it automatically sets full down trim to give better acceleration from a standing start. After a certain (speed, or RPM, or time--I don't remember) the trim automatically moves to the neutral position. It was supposed to help you win drag races or something, but didn't do much in my opinion.

Thanks for that clarification. Not important to me it sounds and nothing that would prevent the 1100 engine upgrade.

[steve45]

Comparing 1100 and 900 on Partzilla I came up with this. I'm worried about accuracy because the carb assembly numbers are the same but I KNOW the 1100 has the accelerator pumps and the pictures on Partzilla even show the pumps? According to this the exhaust, igniter, and even carb assembly are the same but I know I need Carbs with Accelerator pumps and new jetpump (bigger diameter).

Part Desc	900 Part #	1100 Part #
Exhaust Elbow	18049	18049
Header Pipe	59081 / A	59081
Muffler	18180	18180
Water Box	49070	49070/A
Igniter	21119/A	21119/A
Generator Stator	21003	21003
Carburators	15003	15003

You need to look at the 9-digit part numbers. A 18180 is a muffler. It could be a motorcycle muffler, too!

The accelerator pumps are no longer available. Do a search here, as I think somebody came up with a solution, possibly from a Polaris. OR, you could install CV carbs from '98 and later models.

[cocacolaxyz]

The 1100 ZXis had the Kawasaki Automatic Trim System (KATS). You push a button and it automatically sets full down trim to give better acceleration from a standing start. After a certain (speed, or RPM, or time--I don't remember) the trim automatically moves to the neutral position. It was supposed to help you win drag races or something, but didn't do much in my opinion.

I don't like full down trim once I added that nozzle extension. It's too much. Even though I fixed the KATS.....I've never tried it in the water.

[Ttrm007]

You need to look at the 9-digit part numbers. A 18180 is a muffler. It could be a motorcycle muffler, too!

The accelerator pumps are no longer available. Do a search here, as I think somebody came up with a solution, possibly from a Polaris. OR, you could install CV carbs from '98 and later models.

I'm doing a lot of reading and now I'm wondering... Since it is a '96 and I believe it has CDK II carbs, and from what I'm reading, CDK II carbs are preferred to CV carbs.
- The main difference between 900 and 1100 carbs is the jet size and accelerator pump
- Accelerator pump parts are not available (unless I find the alternative)

Do I just re-jet the 900 CDK II carbs and be done?

Thanks for all the input.

Tom

[Ttrm007]

You need to look at the 9-digit part numbers. A 18180 is a muffler. It could be a motorcycle muffler, too!

The accelerator pumps are no longer available. Do a search here, as I think somebody came up with a solution, possibly from a Polaris. OR, you could install CV carbs from '98 and later models.

Thank you!! I was way to optimistic. Most of the exhaust is different. Igniter is different. Now I'm feeling like maybe not worth it. How fast is it going to go anyway? Either way it is more about agility on this one which is why I'm keeping it. It is fun to slice around as compared to my 300x. Thoughts?

Part Desc	900 Part #	1100 Part #
Exhaust Elbow	18049-3753	18049-3764
Header Pipe	59081-3724	59081-3726
Muffler	18180-3711	18180-3714
Water Box	49070-3725	49070-3725
Igniter	21119-3744	21119-3745
Generator Stator	21003-3730	21003-3730
Coil 1	21121-3708	21121-3708
Coil 2	21121-3709	21121-3709
Coil 3	21121-3710	21121-3710
Carburetors	15003-3702	15003-3718

[steve45]

I really don't know what you do to remove the accelerator pump. I would guess that you could re-jet the CDKs. Make the low speed a little richer to counteract the lack of the accelerator pump.

The CV carbs have an undeserved bad reputation. I've had them on 3 'Skis and they worked just fine. They're different, but I've found them to be responsive and reliable. Parts are expensive. I take them apart before I order parts and only replace what's bad.

[Stevis05]

Not sure if you’re still looking into doing this or not but I have a little info to offer. Mostly related to the carb debate: cdk vs cv. From what I understand based on readings, in 1998 the zxi 1100 was fitted with the cv carbs, and main reason was around this time environmental protection laws were drastically cracking down on two strokes for emitting too much bad exhaust into atmosphere. The cv carbs was Kawasakis solution to lessening emissions but still making two strokes. If you dig up the facts, the cv carbs will burn way less fuel per hour than the cdk 2s, and CAN have just as good response. However, a few things to consider: the cv carbs utilize one large fuel pump that no longer has available rebuild kits for, but can be bought entirely new(aftermarket copy’s). The engines that came equipped with cv carbs had only one port near the intake for one pulse line (98-03?) I’ve heard a second pulse line can be added but that’s for another thread. Second, in 96-97 zxi1100 engines, they both came equipped with cdk2 carbs which their engines had two pulse lines cuz they had two fuel pumps. If you read the manual for 97 zxi1100 it explained that after 96 models were out, a common problem noticed was that cylinder 1 had a lean issue, and they added the accelerator pump on 97s to combat that issue. This accelerator pump also has no available rebuild kits. So to wrap up:
96 zxi 1100 engine is best suited with cdk 2, with or without acc. Pump(preferably with)
97 zxi1100 same
98-03 can use either set of carbs, but if converting to cdk2, front pulse line is non existent and needs to be addressed. Likewise, 96-97 motors can use cv carbs is front pulse line is properly blocked off

[Stevis05]

I learned this when I replaced the engine in my 03 zxi1100. I bought a complete motor and carb setup from a 97 and installed it. Every thing was literally bolt and go. Also in 98 the fuel tanks were larger and 15+gallons vs the 13.something of the 96-97. With mine, 15+gallons of fuel, 97 motor with cdk2s with accelerator pump, I get about 1.2 hrs of run time at wide open throttle. And I still run the oil injection system and motor is stock never rebuilt.