I'm looking for some personal experience with Big Bore kits.

If anyone has done any engine upgrades, I'd like to hear

what kit you installed?

did you change the impeller and or fan?

and if there was anything you'd do differently if you did it again.

Any info from dealers would be welcome, but I really want to hear form people that have already done this work.

Thanks in advance.

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2010 Teryx LE, Warn Bumper
MSD,Muzzy's Duel Exhaust, Dalton Clutch Kit,
HW Clutch Cover, Snorkeled, K&N Modded Air Filter,
Black Rhino Gauge pod, Tach, Volt, W temp,
HID Light bar, Odyssey PC925 Battery, 27" Zilla's
Muzzy 840, Stage II cams, 38mm throttle bodies, 324 injectors, Water impeller, new stock crank, rods and barrings

FST kit...best bang for the buck...
Dasa Racing in Riverside did the work...but I also recommend LTI in Anaheim...
I recommend you buy the radiator and/or at least a oil cooler to help with the increased heat of the added cc's...
I kept the stock valves but had the heads ported...DASA and I have built several motors this way and it seems to be a reliable way to build a engine. Spent a considerable amount of time on the dyno to get it just right. Also added the DASA exhaust, Dalton clutch & clutch hat. Don't know if I would try anything different as it has held up for 3 season's now...very happy with it...

Total cost was around $2000 by the time it was said and done...

what he said. i went with the dasa kit and had them build it. stock valves with port and polish... i built an oil cooler for mine, and a multipass radiator. i run the muzzy exhaust and vfj clutch. going on second season now... fast and reliable. as far as jims $2000 price above goes.... that is just for the motor and motor work. clutch, exhaust, cdi, impeller, radiator, and oil cooler are extra!

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Stock 2012 Blue LE Teryx 4.... for now!

Just bought a FST kit, did you install it by yourself or you brought it into a shop to have it installed.

I would say Sandjunkie is pretty close but final cost depends on who does your install. The FST 840 is reliable but you need to do the other extra's to help keep it cool. Radiator, water impeller & oil cooler are a must IMO. Another option is to stay with the stock bore and just upgrade to HC pistons & cams and include some head work, ie valves & porting. It just depends how deep into your wallet you are willing to go.

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2008 LE,TRP 880 w/Forged Rods & trail/race-2 cams, 41mm FCR's, Benchmark modified heads,I-Shock +5 LT kit,K-2 concepts Bed delete,12" Hiper's w/Bighorn 2.0's, Muzzy Pro,Dynatec PG CDI & hot coils,VFJ Clutch Mod's & Dalton,modified PWR rad,oil cooler w/remote filter,DASA gauge POD w/Tach,H2o temp & oil press gauges,Beard super T1 seats, 5 pt harness',PDS custom 2 seat cage w/Alum top,tube doors,front & rear bumpers,40" Rigid LED,Odessey PC 1200,Safeglow Red fiberoptic whips, Amsoil
FULL FIBER SKINZ SKIDPLATES

Well, I bought a Muzzy kit. It's all installed, and I'm just getting the motor in today. I should be able to start my baby tomorrow. HEEHAW!

It's been a long road though... I didn't know my bottom end was toasted as well, so I'm WAY over budget.

It better knock my socks off.

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2010 Teryx LE, Warn Bumper
MSD,Muzzy's Duel Exhaust, Dalton Clutch Kit,
HW Clutch Cover, Snorkeled, K&N Modded Air Filter,
Black Rhino Gauge pod, Tach, Volt, W temp,
HID Light bar, Odyssey PC925 Battery, 27" Zilla's
Muzzy 840, Stage II cams, 38mm throttle bodies, 324 injectors, Water impeller, new stock crank, rods and barrings

I don't think you will need to worry about that. Best thing you can do is find a stock machine close to you that you can drive then drive your machine. Not even comparable.

Have a 2010 840 built by Benchmark and just the Muzzy impeller and a Benchmark oil cooler the car flat out rips. I have no problems with oil or coolant temps. Make sure you put in ARP studs and a catch can other than that you should be done.

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Benchmark Performance

LTI did my BBK and it has ran strong for 2 seasons now I did their oil cooler and siphon break and added a water temp gauge it never see's above 205

Well, it's been damn near a year since it blew my stock engine. Took me a long time to get the motor done up and installed. I drove for 50 miles and blew the head gasket.

Turns out the surface of the cylinder was not cleaned up very well when it was refurbished.

Cost me an additional $1000 buck and three weeks of riding time, but I've got her back again.

I hope the head gasket thing was only a one time thing. If this turns out to be an ongoing thing, I won't be able to afford to fix it again.

Attached Thumbnails

     

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2010 Teryx LE, Warn Bumper
MSD,Muzzy's Duel Exhaust, Dalton Clutch Kit,
HW Clutch Cover, Snorkeled, K&N Modded Air Filter,
Black Rhino Gauge pod, Tach, Volt, W temp,
HID Light bar, Odyssey PC925 Battery, 27" Zilla's
Muzzy 840, Stage II cams, 38mm throttle bodies, 324 injectors, Water impeller, new stock crank, rods and barrings

Hi J, if LTI built your motor you probably have one of our kits (must be a std bore kit if you need a catch can) and water pump. Our water pump is a must for you southern guys as it double's the coolant flow and really keeps the temps down and constant.
Thanks,
Ray

If your having the heads and cylinders machined with a face mill, they have to be MIRROR finish. Ideally they should be machined in a lathe, then the machine marks help hold the gasket instead of creating a path for pressure to leak.
If your making any power with a plated 840, you'll want to have them O ringed as the cylinder flex's a lot and when the cylinder flex's out, it pulls the gaskets surface of the cylinder away from the head.
Ray

I bought an engine kit from Muzzy's. The cylinders were recycled, bored, and nickiciled. I dropped my engine and the kit off at a local builder, (typically a snowmobile shop).

They (nor I) had any reason to believe that the cylinders would need any further prep after spending a grand for them.

The kit came with kermetic gaskets. They have some sort of coating.

My Builder mentioned that he is familiar with "O ringed" cylinders. I wish Muzzys used that technology. Unfortunately they don't.

I don't know what kind of power I'm making. It's got a fair bit more torque than it used to with just the duel exhaust and MSD.

I hope it keeps a seal this time. I had the cylinders and the heads sanded down and got new gaskets.

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2010 Teryx LE, Warn Bumper
MSD,Muzzy's Duel Exhaust, Dalton Clutch Kit,
HW Clutch Cover, Snorkeled, K&N Modded Air Filter,
Black Rhino Gauge pod, Tach, Volt, W temp,
HID Light bar, Odyssey PC925 Battery, 27" Zilla's
Muzzy 840, Stage II cams, 38mm throttle bodies, 324 injectors, Water impeller, new stock crank, rods and barrings

The problem might not have been the cylinders, but your heads. Did you have the heads cut?
I wouldn't sand them down, you can check them that way on a surface plate, just a couple rubs. If you see full contact then you should be good, if you have to sand them flat, you won't be.
Ray

It would be expected that for that kind of money it would be a true flat surface......cant believe a reputable name like muzzys would send out an inferior product.Good luck with the install

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2008 with 240 hours,Fundy STD Bore Kit, Muzzy Duals ,Hunterworks Carb Kit ,Dynatek C.D.I. Uni Filter ,Dalton Clutch Kit +O.D. Cover ,Kolpin Dual Gun Holders ,Warn XT 3000 Wireless Winch ,TYRI L.E.D. Lights,Custom 500 Watt Stereo ,Custom Cut Lexan Windshields , Full Guages and 28 inch Maxxis Mudzillas

Soon to fab 4 seater with boat rack