Yella's ZX7 project

[Yella]

I got back from Dubbo with the shits:( cause I didn't have my bike going and decided I better get to it if I ever want to see it on the road , So I picked up some of the bits I wanted and could afford at this stage and started[8D].I know it's a long way from finish as I put the first spanner on it tonight but I figured I would start a thread to show the progress as slow as it will be. On this the 1st stage the mods will be
shorten an 03 R1 ducktail and fit with integrated indicators in the taillight
shorten the sub frame and raise the angle of the tail slightly
520 chain and sprocket -1 +2
strip off and sell the unwanted/needed bits and clean up
new dash unit
clean up wiring and fit headlight unit and front indicators
find/make exhaust and can (not sure on style yet will work that out as I find bits I like)
mod or get new front guard
Full service and general clean up
get it dyno'd
braided lines and new brake pads
general bling bits
paint and rego
so not much really but enough to keep me busy and with $$$$ :(In short supply it may take a while for some of it to come together.

It was all fairly straight forward tonight me and my offsider found that my bike had gone out with Fimp's and has rocker cover leak and the starter solenoid is playing up nothing huge and had a mock fit up of some bits happy with it so far:D:D
will get some better quality pic's later for now these are off my phone

http://pic70.picturetrail.com/VOL1836/8602720/15960288/243574983.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/243574370.jpg
The start

http://pic70.picturetrail.com/VOL1836/8602720/15960288/243578032.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/243574372.jpg
mock fit up just to see how it will sort of look

http://pic70.picturetrail.com/VOL1836/8602720/15960288/243574966.jpg
stage 2 once it is all running and rego'd I am going to have a go and some extra power.zx9 motor and a turbo maybe will see how it pans out. I have plenty of time to research and hopfully get it right

http://translate.google.com/translate?hl=en&sl=de&u=http://www.zxr-fighter.de/&sa=X&oi=translate&resnum=1&ct=result&prev=/search%3Fq%3Dzxr%26start%3D20%26hl%3Den%26sa%3DN

[Yella]

Slow progress but its getting there

http://pic70.picturetrail.com/VOL1836/8602720/15960288/245704494.jpg


http://pic70.picturetrail.com/VOL1836/8602720/15960288/249863970.jpg


Still need to glass and clean it up but thats about what I was looking for with the tail [8D]:D

[WATEVR]

yella did u cut and any of the wiring in there or have you just repositioned it around the battery etc? pics pls

[dane_ra]

Keen to see the progress on that mate, should look good.

[Gix11]

Keep it coming mate...........

[Yella]

I know I know I am making slow progress but here is something

http://pic70.picturetrail.com/VOL1836/8602720/15960288/254134604.jpg

All the wires and boxes are in the process or have been moved around the battery and I am making up a new harness for everything forward of that

http://pic70.picturetrail.com/VOL1836/8602720/15960288/254134609.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/254134612.jpg
And some new Bling yellow braided lines and new pads should help stop me once it goes again
Will grab some pic's once I have finished the duck tail not much longer

[Yella]

http://pic70.picturetrail.com/VOL1836/8602720/15960288/254380225.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/254380227.jpg

The tail is almost done now:D[8D]:D[8D]

[zx12argh]

mate - that tail piece is coming up great. has it taken you long? it took me ages to get mine right but i'm fucking useless

what sort of lights you going to run in the back?

[Yella]

Thanks Didn't take long only seemed like a couple of hours but maybe it was longer I seem to lose track of time when I get working in the garage.I am going to run a 03 R1 intergrated brake/indicator LED I picked up off ebay

[HueyonaBlade]

M8 love the shorty can......LOL

[Yella]

can't seem to find time of late but I will get it done

http://pic70.picturetrail.com/VOL1836/8602720/15960288/287688953.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/287688952.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/287688951.jpg

Finally feel like it is moving forward not that you can really tell by the pic's but It is getting closer to paint:D I have to finish off the wiring now when I get time so I can test new dash and remote starter

[-Dex-]

Man, thats looking wicked.

[wackyrider]

That's coming out nice.

[Yella]

I know you figured I got tired and couldn't be bother finishing but but you are wrong:D:D kids, work, life seem to keep getting in the way but still moving forward

http://pic70.picturetrail.com/VOL1836/8602720/15960288/366943407.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/366943410.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/366943408.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/366943411.jpg

Finished the test fit up and bike got striped down and cleaned still have to sort the exhaust and a belly but needed to get some thing down so finally got some paint on the frame and started polishing the rest.
Also got some black on the wheels to get away from the gay purple.

And I think I have named the bike Outkast. As it seems since starting this bike I have become the social outcast amonst the people who I use to ride. When asked what I am riding and I explain they ask why and then look at me like a weirdo when I say why not:D

[sen]

Love the stumpy seat/tail unit you made up.. gunna be a tough looking bike when it's finished..

[Bear]

^^ agreed. Short rears look cool.

[Large]

I can't wait to check out next years update:D

[Yella]

Update 2010
as always progress is slow but progress is progress :D
finally got it up to a point that I could take it out of the garage :D[:p]:D and even managed to slip the helmet on and go for shake down test to see what falls off before I put the color on the bike. A couple of little changes need to the duck tail mounts but all is good[8D] Dash works great. I mounted the speedo pick up on the rear brake slide and the magnet on the disc
http://pic70.picturetrail.com/VOL1836/8602720/15960288/389777278.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/390806615.jpg

Still some details I need to make up i.e headlight bracket, mirror mounts exhaust hanger bracket and I will try to make up a new front guard but that can wait for the moment as I want to get rego and head out for a good ride:)

http://pic70.picturetrail.com/VOL1836/8602720/15960288/390806613.jpg
Got a IXIL can, looks the part sounds great and come with extra baffles to quieten it down if you are into that, Me I set it up with out the extra baffles ;)

Over all I happy with the bike now even if it has taken way long to get to this stage[V][V]

[xa-mont]

That Tail looks great!

Good work

[KATO ZX7]

Lookin good mate, Rome wasnt built in a day ;)

[el sammo]

looks way better and a lot lighter too!

[Yella]

Starter work on a belly while the tank, tail and front guard get some paint.
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173721.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173717.jpg
My fav tool and the other side of the belly
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173711.jpg
I made up a jump start trolly with charger just cause I could [8D] so far no real call for it :D

Pick up so bar end mirrors but decided to fit them on the master cylinders for the brake and clutch instead they tuck in nice and tight [8D][8D]
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173689.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173696.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173681.jpg

also got a new fuel cap and some frame sliders will fit these once I give the frame one more go over with the polish
http://pic70.picturetrail.com/VOL1836/8602720/15960288/393173708.jpg

[BANDITROD]

i bet your missus isnt going to happy about that sprocket stain on the carpet .... bike is looking good aswell mate

[Yella]

lucky for me it's only a old rag over a table in the garage,
thanks I am happy with it

[Benz]

Good thinkin with the bar end mirrors bloke..I like it.
Tidies things up, and doesn't widen the bike.
Have you ridden it with them? Elbow monitors, or what?

[fimpBIKES]

mirrors look good, i've had ones on the tl like that for a while now
with the flatbars your arms are out so there is a nice gap under em, not sure about with those clip-ons
keen to find out though ;)

[Yella]

Haven't riden with them in place but sitting on the bike I can sort of see.Will let you know once I get out on the road. I don't tend to use them anyway

[Yella]

Merry Xmas to me :)

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394193137.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394193131.jpg

It has some paint on it SWEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEET

And yes it is yellow [8D] [8D] [8D] [8D]

[TurboKat]

Worlds longest build thread !! But I'm loving this bike, keep em coming Yella. [8D]
How much longer til it's back together & riding?

[Yella]

Hope to have it going for April just have to see if I can get time between work and the rest of life to get it done fuck all to do really so should happen

[Yella]

Now what to do??
I can stick with the polished frame but will I ever be happy with it a little cloudy in spots or do I drop it apart and paint it all black :(:(

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394277853.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394277859.jpg


Maybe just start again with the polishing [xx(]

[timbo]

I like the polished look, but the clouds would give me the shits every time i look at it if were mine

[KATO ZX7]

Polished is the shit :D
but im way too lazy for it

[Yella]

Its getting better
http://pic70.picturetrail.com/VOL1836/8602720/15960288/243574367.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/287688951.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394455035.jpg

A little more


http://pic70.picturetrail.com/VOL1836/8602720/15960288/394454727.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394454723.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394454724.jpg

[8D][8D][8D][8D][8D]

[LKC73]

Yella that is looking very good mate! I like the colour, sure wont miss that on a ride! Top stuff mate.

[skoerbin]

looks good, i dig the tail and rear light, it will be a shame to have to put a numberplate on that

[holyman_999]

Getting better?!?!?!?
That's a bit of an understatement!
It's looking the duck's nutz dude!

[slickncghia]

looks great....except that headlight, they are poo from an aids infected gay monkey

[Yella]

Still gunna have to figure out what to do with the number plate and the headlight is how you say "the right price" so for the moment it will stay, was thinking about pulling out the lights and making my own surround for them maybe stacked instead of side by side we will see

[Yella]

Finally have a pic or 2 of my 7 in the wild

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394571982.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394571997.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394571991.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394571984.jpg

had to see it back together done that,
Now I can pull some of the bits back off to polish or paint as need aswell as make up some other bit (headlight finish belly etc) with a complete picture to clear up what I want :D:D:D not sure if I will ever be 100% happy

Also found I need to move the dash a bit it can not be seen when riding needs to sit flatter nothing big but something I did not expect

[Yella]

quote:Originally posted by fimpBIKES

mirrors look good, i've had ones on the tl like that for a while now
with the flatbars your arms are out so there is a nice gap under em, not sure about with those clip-ons
keen to find out though ;)


Mirrors well I can sort of use them didn't ride far enough to really test but I think they will do just fine

[timbo]

looking good Yella love the color

[Yella]

Started working on a new headlight design
the one I had
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394606538.jpg
the start of the new one, early stages
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394606540.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394606550.jpg
Not sure if I like it yet need to put some more time into it but figured I would post up while I wait for the glass to set
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394606554.jpg
You have to try and picture it complete, painted and fitted etc
Now play nice and let me know what you think should I keep going or start again???

[skoerbin]

it will look good fitted. you didnt want to put the indicators in it too? what did you make the mold out of?

[Yella]

just playing around with it, maybe shorten it down a bit and not sure on the indicators yet probably tuck them away at the bottom.
I used an old KX 125 front guard it was handy the right shape so a bonus

[Yella]

Something about it I am not sure about looks OK on the bench but looks different on the bike maybe to thin and tall??? fucked if I know will look again a little later and pick up some resin to make a fatter version see if I like that more

[timbo]

I reckon it would look a little better if it were a bit fatter and a little shorter but it would only need a small ampunt taken of the bottom just my 2c

[ALBI]

hmmm getting there keep going !!

[Yella]

first try
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394606550.jpg

now shorter fatter please forgive the quality so far its only a rough knock up once Im happy I will use it as a mold

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394625669.jpg

still don't know may scrap it all together

[xa-mont]

i don't mind the second version. the first is way too skinny though.

[alfiestorm]

I rekon cut some angles in it. across the two bottom corners, straighten up the sides and the top. In its current form I think it is too rounded to suite the lines of the bike ?

alf

[xa-mont]

http://i29.photobucket.com/albums/c287/xacoupe/lightchange.jpg


????????

[Yella]

Gunna make up a couple of different shapes units (angles etc)tomorrow after I get back from EC ( doing a suspension check and adjust follow up for a fella from work while he is doing his first track day )anyway did this last night just a little chop here and sand there after looking at some the photochop job from XA for an idea but I think I am starting to like it

http://pic70.picturetrail.com/VOL1836/8602720/15960288/394723429.jpg
http://pic70.picturetrail.com/VOL1836/8602720/15960288/394723428.jpg

still needs something but looks better in real life than the pic

[Yella]

http://pic70.picturetrail.com/VOL1836/8602720/15960288/395929631.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/395929630.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/395929619.jpg

Looks better in the flesh than in the pics

[xa-mont]

That looks sweet. I like how it doesn't wrap right around the lower light. Size looks good too.

[Yella]

OK so I got up today with a clear head and feeling good so I found the fastest way to kill that off
http://pic70.picturetrail.com/VOL1836/8602720/15960288/396145438.jpg

Having never put turbo on anything from scratch or even played with something with turbo and carb's I figured this will be a head fuck[xx(][xx(] but ya get that so after some quick ebaying I picked up a 2nd turbo

http://pic70.picturetrail.com/VOL1836/8602720/15960288/396145444.jpg

figure one would not be enough and it was going cheap :D $40 sweet. Now this will take some time for me to get going but

a little bit of internet research outside the forum and I found this,
http://i655.photobucket.com/albums/uu278/elhunga/IMG_7731-1.jpg?t=1302269005

http://i655.photobucket.com/albums/uu278/elhunga/IMG_8165-1.jpg
And a quick note on what was done,
quote El hunga "Ye thats my baby & yes its a pain in the butt.
I get 300 BHP at the wheel at 25 psi boost.
Only problem it cant be ridden for long as the front wheel is in the air most of the time.
I would like to tell you that I have spent lots of money changing the internals but I would be lying to you if I did.
The truth is the engine internals are pretty standard from Factory.
The original crank & rods are designed to handle high RPM so I choose to take into consideration & use it into my advantage.
What I did was install a 4mm decompression plate to reduce the compression.
The only thing was that when I did that the new chains were to short so I had to put spacers between the tensioner to allow the tensioner to work efficiently.
The cams have been changed from originals, the standard ones work from 9000 rpm to 12000 rpm where max power is.
Now my power output is between 6700 to 9000 rpm thus making the power almost instant when the revs come up thus making the bike slightly difficult to ride around corners unlike original.
Original you can be on 2 gear doing 7000 to 8000 rpm around the corners with no problem when you increase the revs, my beast is on boost so when you turn the corners at that rpm you will be in the air or the rear wheel spinning to trying to beat the front.
I wanted to prove that to turbo a ZXR 750 was possible but also get good power from it as well.
Most people talk about injection which is easier but I wanted to do the standard carbs to show you can do it also, injection would be easier but that to me is cheating.
Anyone can do injection but carbs are very difficult.
Currently on 25 psi boost it stands up on the rear wheel at 300 klms easy. Very scary when its a street fighter.
The only problem I have is when you are on boost you cannot just release the throttle as it would flood the engine from the amount of fuel that has rushed in.
I do have ignition advancers also as well as very large ports in the cylinder head. They have been increase by a further 35% to allow for the extra power increase also the gearbox has been blue printed to handle the power.
The engine can handle it no problem you just have to decrease the power band thats all."

Now he has made some big claims 25psi/300hp at the wheel and all, I’m not looking for that but he has done it to a zx7 so I will read more later
For now if anyone can tell me any helpful info that would be great i.e. approximate fuel pressure required? will I require a rising rate pressure regulator? will I need to adjust cam timing or ignition timing ETC ETC
or just flame away up to you

[EXBEN]

For starters if he's got a 4mm cyl spacer he'd be running about 6.2:1 comp which would be absolutely crap off boost & to increase the port size 35% would make this worse. It would be unrideable. He's either spinning shit or full of it.

[pav69]

ok ben i have considered this aiso for my zxr750 but dont know where to start and you being the kwacka guru you are having done a few now sorry lost count on how many ,what size turbo is good to start with also running carbs i only want about 150-180 hp this is an everyday bike so i dont want big boost just a mild set up.

[EXBEN]

quote:And a quick note on what was done,
quote El hunga "Ye thats my baby & yes its a pain in the butt.
I get 300 BHP at the wheel at 25 psi boost.
Only problem it cant be ridden for long as the front wheel is in the air most of the time.
I would like to tell you that I have spent lots of money changing the internals but I would be lying to you if I did.
The truth is the engine internals are pretty standard from Factory.
The original crank & rods are designed to handle high RPM so I choose to take into consideration & use it into my advantage.
What I did was install a 4mm decompression plate to reduce the compression.The only thing was that when I did that the new chains were to short so I had to put spacers between the tensioner to allow the tensioner to work efficiently.
The cams have been changed from originals, the standard ones work from 9000 rpm to 12000 rpm where max power is.
Now my power output is between 6700 to 9000 rpm thus making the power almost instant when the revs come up thus making the bike slightly difficult to ride around corners unlike original.
Original you can be on 2 gear doing 7000 to 8000 rpm around the corners with no problem when you increase the revs, my beast is on boost so when you turn the corners at that rpm you will be in the air or the rear wheel spinning to trying to beat the front.
I wanted to prove that to turbo a ZXR 750 was possible but also get good power from it as well.
Most people talk about injection which is easier but I wanted to do the standard carbs to show you can do it also, injection would be easier but that to me is cheating.
Anyone can do injection but carbs are very difficult.
Currently on 25 psi boost it stands up on the rear wheel at 300 klms easy. Very scary when its a street fighter.
The only problem I have is when you are on boost you cannot just release the throttle as it would flood the engine from the amount of fuel that has rushed in.I do have ignition advancers also as well as very large ports in the cylinder head. They have been increase by a further 35% to allow for the extra power increase also the gearbox has been blue printed to handle the power.The engine can handle it no problem you just have to decrease the power band thats all."


This guy is full of shit.
So he's making 300 at the wheel on 25psi boost on what looks like a T25 turbo that would struggle to make 250hp, he's got no intercooler so his intake charge would be absurdly hot,he's running ignition ADVANCERS?? with that much boost you would want to retard the ignition not advance it, it stands up on the rear wheel at 300km/h call me cynical but I think not, & can someone explain to me how Blueprinting a gearbox increases it's strength??

[EXBEN]

You gotta love the internet...

[EXBEN]

quote:pav69 Posted - 09 Apr 2011 : 07:41:21
--------------------------------------------------------------------------------
ok ben i have considered this aiso for my zxr750 but dont know where to start and you being the kwacka guru you are having done a few now sorry lost count on how many ,what size turbo is good to start with also running carbs i only want about 150-180 hp this is an everyday bike so i dont want big boost just a mild set up.
I hate to be a downer but I wouldn't have a turbo bike with carbs as an every day bike.
T25 size turbo is a good start for a mild setup, personally I prefer the GT series roller bearing Garrets though like a GT2554.

[pav69]

how much mucking about to convert to efi custom inlet computer etc ballpark figure with you doing the fabrication work

[hyofighter]

hey pav im with ben on the t25 thing , i use to have a et pulsar turbo and the t25 was a standard item , factory set at 7psi was fine but i intercooled it and ran 10psi and as high as 13psi but after destroying the turbo research found the turbo just couldnt handle the boost , the roller bearing gt series are much better stronger , longer life and have been told that they spool up earlier too

speak to rocket about turbo and carb setups i know him and rockhard got it sorted in the end but i remember him saying it was a head f$ck

[hyofighter]

have you thought about a draw through turbo system like the old mr turbo kits , single carb before turbo no intercooler still with low boost and a standard internals should make good power

[Yella]

quote:Originally posted by EXBEN


quote:And a quick note on what was done,
quote El hunga "Ye thats my baby & yes its a pain in the butt.
I get 300 BHP at the wheel at 25 psi boost.
Only problem it cant be ridden for long as the front wheel is in the air most of the time.
I would like to tell you that I have spent lots of money changing the internals but I would be lying to you if I did.
The truth is the engine internals are pretty standard from Factory.
The original crank & rods are designed to handle high RPM so I choose to take into consideration & use it into my advantage.
What I did was install a 4mm decompression plate to reduce the compression.The only thing was that when I did that the new chains were to short so I had to put spacers between the tensioner to allow the tensioner to work efficiently.
The cams have been changed from originals, the standard ones work from 9000 rpm to 12000 rpm where max power is.
Now my power output is between 6700 to 9000 rpm thus making the power almost instant when the revs come up thus making the bike slightly difficult to ride around corners unlike original.
Original you can be on 2 gear doing 7000 to 8000 rpm around the corners with no problem when you increase the revs, my beast is on boost so when you turn the corners at that rpm you will be in the air or the rear wheel spinning to trying to beat the front.
I wanted to prove that to turbo a ZXR 750 was possible but also get good power from it as well.
Most people talk about injection which is easier but I wanted to do the standard carbs to show you can do it also, injection would be easier but that to me is cheating.
Anyone can do injection but carbs are very difficult.
Currently on 25 psi boost it stands up on the rear wheel at 300 klms easy. Very scary when its a street fighter.
The only problem I have is when you are on boost you cannot just release the throttle as it would flood the engine from the amount of fuel that has rushed in.I do have ignition advancers also as well as very large ports in the cylinder head. They have been increase by a further 35% to allow for the extra power increase also the gearbox has been blue printed to handle the power.The engine can handle it no problem you just have to decrease the power band thats all."


This guy is full of shit.
So he's making 300 at the wheel on 25psi boost on what looks like a T25 turbo that would struggle to make 250hp, he's got no intercooler so his intake charge would be absurdly hot,he's running ignition ADVANCERS?? with that much boost you would want to retard the ignition not advance it, it stands up on the rear wheel at 300km/h call me cynical but I think not, & can someone explain to me how Blueprinting a gearbox increases it's strength??



As said some big claims and mods that don't seem to work together but this is the internet and anything goes :D:D:D
I was thinking the same with blueprinting the box but again this is the internet and maybe things work differently O/S [:p][:p][:p]
Anyway back to the research

[Yella]

So a weekend in the shed and we have this,
http://pic70.picturetrail.com/VOL1836/8602720/15960288/396511778.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/396511775.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/396511781.jpg

And
http://pic70.picturetrail.com/VOL1836/8602720/15960288/396511919.jpg

http://pic70.picturetrail.com/VOL1836/8602720/15960288/396511927.jpg

My first attempts.
All coming along :D[8D] exhaust is almost done and the intake side is taking shape

This will be done on a tight budget so as always it maybe a little slow :(

[DellRoy]

Hey mate, nice zx7 project, i was going to turbo my zx7 also but i ended up deciding to start another project, i have an adjustable CDI if you are looking for one for the zx7, its a vance & hines and has ignition timing for turbo charged motor option, even cams and RPM limits.

[Booster]

http://www.psychobike.com/forums/turbo-nitrous/67185-zx9r-turbo-winter-mods-2.html

you may find this interesting

[kevkatana]

Just put a 9 in it. Less fucking around for same ish result.

[Yella]

quote:Originally posted by Achtung

Hey mate, nice zx7 project, i was going to turbo my zx7 also but i ended up deciding to start another project, i have an adjustable CDI if you are looking for one for the zx7, its a vance & hines and has ignition timing for turbo charged motor option, even cams and RPM limits.


Thansk,
How much do you want for the CDI, everything it on a budget :( but I need to sort ignition timimg.
I can't seem to find much info on them are they boost ref, programable or pick one of a set number of advance curves

[Yella]

quote:Originally posted by Booster

http://www.psychobike.com/forums/turbo-nitrous/67185-zx9r-turbo-winter-mods-2.html

you may find this interesting


Sweet thanks[8D]

[Yella]

So its coming alone waiting on parts but some did show up[8D]
http://pic70.picturetrail.com/VOL1836/8602720/15960288/396970147.jpg

Damper fitted

http://pic70.picturetrail.com/VOL1836/8602720/15960288/396970089.jpg

Almost ready to start it up with the turbo installed just gotta wait for some last bits to arraive and make up an oil feed hose so maybe next weekend [8D][8D] then I just gotta tune it [8)]

[pav69]

wheres those levers and pics of plenum

[Yella]

Soon mate just waiting on the blooy postie for the rest of the stuff

[Yella]

http://pic70.picturetrail.com/VOL1836/8602720/15960288/397077540.jpg

fuel reg and pump in place.

http://pic70.picturetrail.com/VOL1836/8602720/15960288/397077541.jpg
first attempt will see how this works

should get it started tomorrow I hope still waiting on some gauges to arrive but can get it started with out wont hurt :D

[Yella]

Also picked up a second ignition rotor to play with and see if I can get it how I would like

[Yella]

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011561.jpg
CDI in place

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011565.jpg

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011562.jpg

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011564.jpg

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011567.jpg

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011563.jpg
Oil feed and return lines done scavenger pump fitted had to make up the fittings on the turbo for both oil and water. Exhaust done back to the muffler again. Fuel pump and scavenge pump wired up with a relay using the original fuel pump wires for the signal.

http://i1234.photobucket.com/albums/ff419/YELLAZX7/04062011566.jpg
Working on the hose / pipe work for the intake. I was hoping to post up a start up vid tonight but due to some general fuck ups I have to have a little rethink on a couple of pieces so it will delay start up a little not sure how long yet cause I don't know how to solve the problem yet but I am working on it.

[Booster]

Getting there :)
those oil pumps don't move a real lot of oil, you may need to see how much oil comes through the turbo and check the pump can keep up .

[Yella]

I was thinking the same. It tells me it will move 1.8 litres a minute but figured it would be a suck it and see on if it was enough. I have restricted the inlet side of the oil feed down to a 3mm hole not sure on the oil flow required again will have to keep an eye on it

[Booster]

If it gives trouble you could keep reducing the restrictor size, If your your oil pressureis 50 psi or better 1mm should be safe

[Deano]

Check valve after the pump on the oil return? Or is there a check in the pump?

Keep an eye on water temp aswell. Never seen anyone actually use the water cooling on a turbo bike

[Booster]

I tried water cooling several yrs ago, all good most of the time... but... if you pushing hard then slow down, like into town, and low engine rpm don't circulate the water fast enough you will get localised boiling at the turbo, pushing water out of your radiator , potentially then causing overheating issues..

[Yella]

Will it run OK with out it water hooked up, just figured it was avalible why not use it but if it is going to cause issue then I can go without

[Yella]

After stuffing around with Pav in the shed today making up a heat shield and bits and pieces took it for a little ride in the rain [:o)] .Boost came on at about 5-6000 RPM :D[:p]:D needs fueling sorted bad ( gotta figure that out[B)] gotta get smarter in a hurry ) and I now have oil in my everywhere so will need to look at that either turbo seals or return pump not pumping enough or both or all fucked if I know [B)]:([?] will be next weeks problem for now

[BANDITROD]

Jeez you don't fuck around do ya mate good stuff

[Yella]

Trying not to fuck around any more <s>want</s> need it back on the road

The bike would rev free until the boost started to climb then started to miss/starve for fuel and would not rev over 6000 rpmish.
Just doing some of my best thinking and figured I may need to move the the boost ref line for the fuel regulator currently its on the manifold under the carby. Thinking it may do better on the 'T' into the float bowl ref line . Anyone have <s>an opinion</s> any helpful advice on the matter

Gunna rebuild the turbo next week but will run some tests on the return pump and the flow rate required over the next couple of days

[fimpBIKES]

vids!!!

[pav69]

it was a nice smoke show after running for a while

[Booster]

You need your boost reference for bowl and reg from the same point, preferrably in the up pipe pointing toward the incoming air , so the pressure in the bowl and fuel pressure are always a few % above manifold pressure , then your 95 main jet will act as a 100 jet on moderate boost and 105 on high boost which is exactly what you need for matching the jetting with air density and flow , a well setup system can actually need a slightly smaller main jet to run perfect
all this only works if the system is well sealed, you may have to pressure test your inlet system
Easily done by capping the turbo inlet and putting an fitting to add regulated air at about 10 psi
you can then test your fuel pressure rise , (it will only match the pressure without dynamic airflow) and test for leaks
ignor the air passing through the turbo drain

[Yella]

quote:Originally posted by Booster

You need your boost reference for bowl and reg from the same point, preferrably in the up pipe pointing toward the incoming air , so the pressure in the bowl and fuel pressure are always a few % above manifold pressure , then your 95 main jet will act as a 100 jet on moderate boost and 105 on high boost which is exactly what you need for matching the jetting with air density and flow , a well setup system can actually need a slightly smaller main jet to run perfect
all this only works if the system is well sealed, you may have to pressure test your inlet system
Easily done by capping the turbo inlet and putting an fitting to add regulated air at about 10 psi
you can then test your fuel pressure rise , (it will only match the pressure without dynamic airflow) and test for leaks
ignor the air passing through the turbo drain


Sweet thats what I was thinking. Had it in the wrong place
http://pic70.picturetrail.com/VOL1836/8602720/15960288/397077541.jpg

Will move it to the small pipe across the throat that goes to the float bowls hope that will solve one issue.

Gunna start putting together another plenum shortly slightly different shape with a new base plate to help it seal. Or maybe just a new base plate will see as it goes on

[Booster]

what size hole in the small pipe, that system should work ok, maybe just need larger hole or moved further from plenum

[Yella]

7mm ID pipe cut out like VVVV
http://pic70.picturetrail.com/VOL1836/8602720/15960288/397261650.jpg

Will move the ref hose for the reg to this pipe friday night.
Gunna clean up the oil see if i can turn the centre to get the drain more vertical ( think it maybe part of the problem?) make up a new drain pipe and fittings and see what happens Saturday :D:D:D:D:D:D:D:D:D[8D]

[mr.zxr]

i run the same scavange pump on mine and works fine. 3 yrs so far. i had the oil everywhere issue aswell. i put a restrictor in the oil feed line and it solved all my probs. basically the zx7 has heaps of oil pressure and i was over oiling the turbo. it would pass the seals then go everywhere.

[mr.zxr]

also i noticed your turbo is below your sump level. you'll probably have to put a one-way valve in your oil feed line otherwise it will flood the turbo with oil when your parked. i had all the same probs when i first turbo'd my zxr.

[Yella]

What size did you go down to I am at 1mm now at the fitting going into the turbo I was thinking of trying a .6 or .8 mm but think it maybe to small

[Yella]

Going to have the oil feed line above the oil line when I rotate the houseing to stop gravity feed wehn not running,its OK now when on the side stand just on the race stand it seems to be a issue

[latheboy]

I have 3 pitot pipes in the up pipe, 1 goes to the fuel reg and the other 2 go to the carby's. Each feeds 2 carby's.
I've also got the pitot's mounted at 45° facing into the air and slash cut at 45°.
I tried a pitot just like what you have and it didn't work for me. With the setup like yours it wouldn't rev and leaned out as the boost come on.

Not to say it won't work it just didn't for me, plenty of people on OSS have done it this way and it worked.

I think you should rotate the bearing housing of the turbo so the oil goes striaght in the top and drains out the very bottom. If the drain is not at the bottom there will always be oil inside and in can get past the seals.

[mr.zxr]

quote:Originally posted by yella

What size did you go down to I am at 1mm now at the fitting going into the turbo I was thinking of trying a .6 or .8 mm but think it maybe to small

I'll have to have a look and get back to you. can't remember.

[Yella]

Been fucking busy with work gotta hate stocktakes. Finally got an hour to look over the bike pulled the turbo off. Checked it over and found a big fuck off chunk of carbon blocking the oil return fitting must have been sitting in the housing and come on with the additional heat/oil. Sweet at least I found a fault go to love a result. Gunna spin the turbo a little and change the place the oil feed comes from etc and will have it out for another test Saturday.