What was I just saying the other day about not seeing very many mix and match frames and engines in custom bikes? Bill Shank thought we might like to see what he put together in his garage, his KR800, a Kawasaki ZZR1200 mated to a Rotax 800cc 2 stroke engine from a 2003 Ski-Doo. He isn’t the first to mount a snowmobile engine in a motorcycle, but it’s an interesting combo that, with a bit of refinement, could make for quite a bike.
Bill wanted to build a 2 stroke street bike to run with current sport bikes. He started designing the project 6 years ago, using as many stock and aftermarket parts as possible to keep the costs down. After three years of free nights and weekends, his KR800 was ridden for the first time and he has titled and licensed it as a “specially constructed” vehicle in Pennsylvania.
Rolling chassis: Stock 2003 Kawasaki ZZR1200 w/ 1-1/8”dia 1020 tubing fabricated engine cradle
Engine: 2003 Ski-Doo Rotax 800SDI (2 cyl 799cc reed induction w/pneumatic power (RAVE) valves, fabricated steel slotted engine plate with urethane bushes (vibration isolation)
Induction: (2)Mikuni 44 SBN carbs mounted on owner fabricated manifold, Vforce-3 reed valves
Lubrication: Stock oil injection w/2qt tank
Fuel: 91oct pump gas, 5.2 gal tank w/external press/vac breather, Mikuni 35 lph diaphragm type fuel pump
Ignition: Ignitek programmable 12vdc CDI w/rev limiter and power valve outputs)
Electrical: 12v-360W Alt/reg-rect w/sealed maint free battery, 40A ckt breaker, Painless (7)ckt fused power distribution
Starter: Modified Honda 390 recoil pull start with owner modified engine pulley
Transmission: 2004 “STD” HD 5spd Softail with custom mounting plate, relocated drain, vent and fill points
Primary Drive: 2004 Rivera 1.75” belt drive/ hydraulic actuated Pro Clutch
Exhaust: CPI Racing custom exhaust w/ 2 into 1 manifold, 4.5” ground clearance
Instruments: Dakota Digital Speedo/Tach, engine temp gauge, neutral and power valve indicator lights
Weight: approx. 525 lb dry
Performance: +100 RWHP on dyno, Top speed:150-170mph
As I said above, a few refinements would be nice. A pull starter? OK, it works, but maybe at least a kick start instead. The engine cradle is also among the “it works” pieces but it certainly needs some redesign. The Softail tranny with open primary is an interesting combo in a sportbike, too, however, the thing to remember is the bike runs, it puts out very respectable power (100+ RWHP) and is currently licensed for the street. I would consider this sort of a proof of concept that could be taken much further. It’s a neat idea, I respect the work done so far and, perhaps, someone could run with it and add some polish. Interesting.