GSXR813 Turbo EFI

[slingy88]

And a couple with the coolers on

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/21042013156_zps515b4de8.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/21042013156_zps515b4de8.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/21042013157_zps48a039e9.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/21042013157_zps48a039e9.jpg.html)

Its all going ok but the V band fitting is quite big and has ended up virtually touching the oil filter. So i either piss it off and use a short bit of 63mm pipe tp join the headers to the turbo which will give heaps of clearance and still aloow the filter to come off or get a remote filter kit.

Anyone know of a compact remote filter kit that might be suitable?

Though leaning towards fucking of V-band fittng to keep it simple.

[slingy88]

Or maybe a slightly shorter filter? Any ideas?

[slingy88]

I do like the V-band as it gives me the option of changing to a different turbo by just making up the flange and V-band bit . But not the end of the world if its gotta go.

[Surt]

a remote oil filter is what i gunna do just because i'd be able to change it without removin a pile of turbo shit like dump pipes and wg

[slingy88]

Mmmm....that was my idea with the V-bands, just drop the turbo to get acces to the filter bit i dont think its gonna work out.
Have you found a good one to use yet?

[Surt]

there are plenty of them on ebay but im gunna make my own cept fittings and hoses slingy

[slingy88]

Got the last header in last night. Still not sure what to do with the V-band issue. Just using a bit of 63mm pipe to join the turbo to the header will give me plenty of room for the filter but will have to take the header off to change the filter. (Not too big an issue for the amount of K's i do lol) Or use the Vband and install a remote filter kit, but this is just more bits to find homes for, more weight and more pipes to fail etc. But will make filter changes easy and turbo fitment easy as well. Pro's and cons to both, and both about equal i suppose.

Anyway, this is where i am up to know.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/22042013158_zps9de860cb.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/22042013158_zps9de860cb.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/22042013159_zps88a38671.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/22042013159_zps88a38671.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/22042013160_zps8ea2dd4e.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/22042013160_zps8ea2dd4e.jpg.html)

Run out of Argon now so might take a few days to get a refill.

[ozzy1100]

to late now but just looking and thinking a water to air intercooler then you only have another fuild cooler to fit or even like deano's
oil cooler in the tail and air to air higher up but like i said to late now.
looks shit hot tho good luck

[slingy88]

Yeah, seems like every system has its pro's and cons. Didnt like the idea of having to relocate the oil cooler in the tail. I did look at it but fuck all room without changing to a more kicked up tail and relocate the electrics but then the way i'm doing it now is turning into a ball ache as well lol. Alwas fancied making a liquid to air intercooler setup using the fuel as the coolant and the fuel pump to move the fuel around the circuit so as not to double up on stuff. One day maybe.

[ozzy1100]

half the fun is running all the diffrent silly ideas swiling around in your head to see if they would work :-)
Im hopeing in the near future to be given the chance to get blown by a mechanic in drag....
all good fun lol

[slingy88]

OOHH, mechanical fuel injection, that sounds fun :D

[evad]

Looking good :D

[Deano]

Wow that turbo looks LOW
Hope you don't plan on going over a speed hump

[slingy88]

Wow that turbo looks LOW
Hope you don't plan on going over a speed hump

It does but the white board its sat on is set at the height of the bottom of the muffler, so its no lower than that, and the muffler fitted inside the origional plastics so its no lower over all ground clearnace than a stock bike with the plastics on, so should'nt cause any problems, just need to make sure i get it looking good over all.

[Deano]

You should be right then. Carry on

[slingy88]

That i shall Mr Deano. Just got the turbo mounted on the headers and removed the jack and its all looking pretty damn good. It is actually higher i think than in the above photos, as i ended up pissing off the Vband and just welding the flange to the headers.
So deffo need to remote oil filter it know.

[Deano]

If you were running a Garrett you could just buy the tial s/steel exhaust housing and that would save height

[slingy88]

Been chipping away at getting the fabrication done. Nearly there, all the main work done, just gotta strip out the IC and plenum to finnish welding and paint, then get the top end of the motor assembled before a final build is done.
So this is were its at now.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/28052013204_zpsac9de746.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/28052013204_zpsac9de746.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/28052013207_zps5e4654d0.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/28052013207_zps5e4654d0.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/28052013208_zps6e742787.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/28052013208_zps6e742787.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/28052013210_zps9fb3c9c2.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/28052013210_zps9fb3c9c2.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/28052013211_zps473f9422.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/28052013211_zps473f9422.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/28052013213_zpsadeecfa3.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/28052013213_zpsadeecfa3.jpg.html)

Pretty happy with hows its all going so far. Cant wait to get it back running again ;)

[K6Thou]

What's the plans for the paint mate ?

[havoc]

Awesome, glad I found this bike and yourself again :)

[slingy88]

What's the plans for the paint mate ?

I was refering to painting the top end of the motor and IC, but my over all plan is for it, is for satin black frame, swingarm and possibly wheels with some sort of blue/white angled design hommage to Suzuki. But thats gotta wait untill i get it running right.

[slingy88]

Awesome, glad I found this bike and yourself again :)

Likewise MR Havoc ;)

[ozzy1100]

Lovely fab work

[evad]

Great progress, well done.

[slingy88]

Thanks guys.

She's still no show pony, and probably never will be (can't polish a turd as they say), but slowly getting the quality of the fabrication up and hell, it makes me happy which is whats counts lol.
Got a guy lined up to clean up the head so that will give me more time to sort out the wiring and other small jobs.
Also going to pull out the Bluetooth adapter and send it to my brother so he can make the link to the htc dash more stable and reliable, in preparation for getting it running and doing some tuning.

[evad]

Have you got the dash back yet?
You are still running stock internals in the motor?

[slingy88]

Have you got the dash back yet?
You are still running stock internals in the motor?

Nah, not until my brother has finished working his magic on it.
And yep, still running all stock internals, just a 1mm spacer under the barrels and APE head studs. Should give me 9-1 cr which is nice and street able but will still allow me to run 15psi of boost. Obviously always going to be running the risk of crushing ring lands with the stock cast pistons but think this is more a symptom of detonation which is a lot easyier to avoid with efi so will give it a crack. Can always go Busa pistons later if necesary.

[slingy88]

Got a bit more done.
Saturday i got the remote filter head mounted. It dosnt hang down below the exhaust so shouldnt catch on anything, but cant go much higher as pipe inlets wont clear sump otherwise.

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/03062013220_zps88a551ea.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/03062013220_zps88a551ea.jpg.html)

[slingy88]

Then last night i wnet out to the shed with a beer at about 9:30pm just to have a look and formulate some ideas, which turned into a 3.5 hr session on the lathe and TIG to come up with this.
Its a piece of 80mm machine rod, left over from making the outrigger bearing support turned up into a sandwich plate cover. A spare oil filter was relieved of its square section seal, and a groove machined to take it. Then a bit of 25mm rod was drilled, reemed, threaded (M20X1.0) and one end turned down to fit the hole in the sandwich plate. Then i bored a 25mm hole through the cover and TIG'd in the 25mm end of the above threaded section into it. So this cover can just be spun on and tightened like a filter to hold the sandwich plate on.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/03062013218_zpsca77dd0a.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/03062013218_zpsca77dd0a.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/03062013219_zpsf11c430c.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/03062013219_zpsf11c430c.jpg.html)

Which fits with this slightly modded Chineese sandwich plate.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/03062013216_zpsea1fdee0.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/03062013216_zpsea1fdee0.jpg.html)

To give me this. Think i might run over the weld again to clean it up a bit.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/03062013215_zps5df1f446.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/03062013215_zps5df1f446.jpg.html)

I'm thinking of actually bending up some rigid 12mm alloy tube sections between the sandwhich plate and the filter so theres no rubber to leak and no supports required under the sump. Just need to check that i can do it and still get it off if its all solid.
But i think it should work out ok.

[Yella]

Love this build

[slingy88]

Love this build

Cheers Ian,

Have to say, i always look forward to your thread updates. That Busa is going great guns ;) From small seeds big trees grow lol

[slingy88]

Gee's, things have slowed down again.
:(
the other weekend i made the oil return setup. I will just let the pictures do the talking.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/09062013236_zps39a39273.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/09062013236_zps39a39273.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/09062013238_zps4ebc4bc1.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/09062013238_zps4ebc4bc1.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/18062013239_zps2a3f2f6f.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/18062013239_zps2a3f2f6f.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/18062013242_zps4eb35e53.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/18062013242_zps4eb35e53.jpg.html)

Time to put the top end of the motor together now properly. :D

[ozzy1100]

what a pain in the ass little piece, top job

[slingy88]

what a pain in the ass little piece, top job

What an apt description lol.

It took a couple of goes to make the little U shaped pipe as its only 1mm wall alloy and welding around
the mitres was a little touchy, but its all good practice.

[ozzy1100]

Can't wait till my new fab area is done and the new tig is working
Then I to can wish I wasn't so clever when trying to make such pieces lol

[ozzy1100]

Pulse?

[slingy88]

Pulse?

Nah, not enough control on this type of material, just low amps and moving around the piece to hlep disipate the heat.
I do use pulse quite a bit though. Pretty good for the IC etc and helps when learning i think as you can use the pulse as a timing que . ie Pulse, dab filler in puddle, move, pulse,dab filler in puddle, move, pulse................etc

[ozzy1100]

I have had pulse on a few of my dc machines over the yrs and really find that it rarely adds much that i cant do with out it,
I just moded jules's ti exhurst link pipe( first time with ti ) and found pulse with the purge worked well with gap fill but I found welding much nicer with out it.
the miller ac i just got has full funtion but really all I was looking for in a ac machine was ac ballence and herz, btw I think the pulse dab pulse dab is called bunting but dont quote me on that lol
good design on the pump bracket btw....britten had a thing where ever part had to do at least 2 jobs looks like your comes in at three at my count :-)

[slingy88]

Bunting aye...... right or wrong you've given it a name and i'm sticking with it lol.

My dad always instilled in me the idea to design by function and to simplify where ever posible.
The simplest designs are often the best and this then brings its own style.

[ozzy1100]

I think your old man knew my old man lol

[slingy88]

Well, got the barrells cleaned up, deglazed and painted. Then pulled the rings off and cleaned the piston crown to find this.

Its a bit hard to see but thats a 0.5 on the piston crown. Nice :D

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts004_zpsc61f2267.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts004_zpsc61f2267.jpg.html)

[slingy88]

But whatever numpty put the rings on didnt put 120deg seperation between the ring gaps. Especially the oil control rings which were about 5mm apart. So that might explain why there was so much coke on the crowns.

Then i turned my attention to finnishinh off the remote filter fitting.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/bikeparts002_zpsbf74e608.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/bikeparts002_zpsbf74e608.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/bikeparts005_zpsd9fd963f.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/bikeparts005_zpsd9fd963f.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/bikeparts008_zpsecd19a8e.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/bikeparts008_zpsecd19a8e.jpg.html)

Pretty happy with how it came out.

Just gotta get the head sorted so when that goes on i can it all together propperly.

[ozzy1100]

lol bet that hard pipeing between to fixed piont was fun .... looks the dogs tho

[slingy88]

lol bet that hard pipeing between to fixed piont was fun .... looks the dogs tho

Mmmmm....... lets just say my scrap bin has gained quite a few odd shaped lengths of tube lol

would have been so much easier without the swap from one inlet to the other.....

[ozzy1100]

Mmmmm....... lets just say my scrap bin has gained quite a few odd shaped lengths of tube lol

would have been so much easier without the swap from one inlet to the other.....

well running tube for a living I can tell how fucked that would have been but came up a treat and tho no one ever will see every time you do puts a smile on your face :-)

[evad]

Nice work Jack!!! Love it

[slingy88]

well running tube for a living I can tell how fucked that would have been but came up a treat and tho no one ever will see every time you do puts a smile on your face :-)

True, it also puts a smile on my face that it only cost $35 (and some time) Probably wouldnt have got a length of braided line for that let alone any of the othe bits lol

[slingy88]

Nice work Jack!!! Love it

Cheers mate. Did you get that slabby motor lubed up yet?

[ozzy1100]

True, it also puts a smile on my face that it only cost $35 (and some time) Probably wouldnt have got a length of braided line for that let alone any of the othe bits lol

I not long ago did 25mm clean air copper line system for a client my price installed was less then they where going to pay for flex..
and they tell me Im to dear lol

[evad]

Yes I did. I must get your plug spanner back to you!!

[slingy88]

Yes I did. I must get your plug spanner back to you!!
no rush mate, that wasnt why i asked. Just wondered if you'd had any luck which you have so all good

[slingy88]

Really need the head sorted before any real progress can be made but there is a heap of little shitty jobs to do, so one of the next ones to get tackled is the adaption of the turbo inlet to take the filter.
So, hack sawed the inlet tube off at the angle required to fit the filter. This left it very thick compared to the 63mm tube that was being used to mount the filter on. so decided to throw it in the lathe and turn it out a bit.

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts018_zpsf607a76c.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts018_zpsf607a76c.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts019_zps345e7e54.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts019_zps345e7e54.jpg.html)

Then welded the stub on. Couldnt get the TIG torch around the top of the tube so ended up welding around the inside as well which actually did a real good job of blending the last edge inside between the housing and the tube.

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts020_zpsc573bd85.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts020_zpsc573bd85.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts021_zps879a9219.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts021_zps879a9219.jpg.html)

Just got to drill tap and plug the old nipple hole for the wastegate reference as it fouled the filter and the housing can go back on the turbo.
Gonna run a reference for the wastegate straight from the plenum. This way, i can T the boost controller in close the plenum and only run a single line down to the actuator, plus the wastegate will opperate at the pressure the engine is seeing, not whats in the housing, so should be abit more responsive i think.

[Yella]

We need a like button. LOVE IT

[pav69]

very tidy job come up a treat ,but i didnt know suzuki were sending there bikes to volvo to get them turboed

[slingy88]

very tidy job come up a treat ,but i didnt know suzuki were sending there bikes to volvo to get them turboed

No, not many people do. Mitsubishi produced a limited number of TD04's spec'd to suit a small production batch of the larger Suzuki's as well as some lardy models of Volvo's and to keep costs down it was decided to keep a single brand name on the unit.
It was deemed that the Volvo's sales would drop considerably if there was any brand association with the ritiously awesome renegade outlaw Suzuki, as it stood against all that was safe and steady and average Joe Volvo.
Where as Suzuki customers only coverted speed and power and boosted coolness and as long as its heart was Suzuki, cared not for brand names or conforming, and so the decision was cast to brand all units Volvo.
Now, these Suzuki/ Volvo hybrids are extremely rare, so rare that there are no real factory records, or dealer acknowledgement of there existance, but my friends , they do exist. If you look long enough, and you are true of heart, and pure (ish) of soul, maybe you can find one to.

[ozzy1100]

Lol top
Job

[slingy88]

F#@k (F#@k) Yeah !!!

She's a runner again.

Tried to get it going yesterday but failed. Filled it up with fuel and decided to overide the fuel pump to prime all the rail up and get all the air out prior to cranking, only to have every fuel rail O-ring fail and drown the entire motor ( and floor) in petrol. DOH!!!
So, got some new O-rings today and through it back together and after a couple of cranks it fired up and idled nice up to temperature. SWEAT!!! No oil leaks or anything else that i could see, and no smoke or oil drops from the exhaust so the scavange system must be OK too.
The only problem to fix is it isnt charging so just need to sus that out. Its the same generator i was running on the 750 so i know it was working.
I'll post some pictures and video as soon as i get a chance.
Oh, and the HTC seems to be playing th game now as well so cant wait to get some good tuning and data logs done.

[slingy88]

Well, as it turns out, not quite so F#@k Yeah!!

The first couple of times it fired up good, then with the threat of a saturday ride, it started smoking like a bastard.
Quicky tracked it to my awesome $100 turbo gushing oil out of both inlet and exhaust sides of the centre. Initially thought i was getting syphoning of oil from the feed side, filling the housing with oil, but after a bit of testing realised it was the turbo leaking, so pulled it apart.

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/bikeparts044_zpscbbcebc9.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/bikeparts044_zpscbbcebc9.jpg.html)

All the internals are actually in top condition which is good, but the oil spinner on the exhaust side was completley carboned up, allowing the oil to flow straight across it and escape, while on the compressor side, a small O-ring that seals the bearing plate to the centre housing has succombed to age and was passing oil into the compressor housing.
So, i have a Genuine Mitsubishi rebuild kit (as it wasnt really much more than a no name copy kit) winging its way to my door, so hopefully should be back in action shortly.
In the meantime, i've made a propper mount to hold the bycycle speed sensor rather than having it banded to the fork lower which wasnt great, and i have some mirror mounts coming as well so i can finnaly get them fitted too.

[slingy88]

So, turbo is rebuilt and is no longer passing oil.

But with some more investigation, it would also seem that after engine shutdown, the oil feed to the turbo keeps passing oil untill all the gallerys in the head and block above the turbo feed point have emptied, then it would stop. This amount of oil was about 50ml, which was more than the volume of the return pipe from the bottom of the turbo to the scavange pump. So in theory, this could fill and back oil up into the bearing housing as well. So decided i would have to make a larger volume oil drain sump under the turbo to cope with this.
So here it is compared to the old one.
http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts046_zps8163dfd4.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts046_zps8163dfd4.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts047_zps21c5e765.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts047_zps21c5e765.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts049_zpsbb949a10.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts049_zpsbb949a10.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts050_zps209859d2.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts050_zps209859d2.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts051_zpsdd80ca7c.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts051_zpsdd80ca7c.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/bikeparts052_zps91d43d8d.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/bikeparts052_zps91d43d8d.jpg.html)

Just need to test this setup but but pretty sure it should work ok now.

[Yella]

Nice

[slingy88]

Finally got it out into the daylight and took it for a spin, sadly my crappy little camera didnt turn on so no riding footage but a couple of quickys of it in the drive.

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/23102013328_zps0c9ac8e4.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/23102013328_zps0c9ac8e4.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/23102013329_zpsdd1974da.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/23102013329_zpsdd1974da.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/23102013330_zps92b170b4.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/23102013330_zps92b170b4.jpg.html)

And a quick walk around
video, just click the picture
http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/th_23102013004_zps234c0cfe.jpg (http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/23102013004_zps234c0cfe.mp4)

And a video of the first fire up straight from the shed

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/th_23102013006_zps98b2e2d0.jpg (http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/23102013006_zps98b2e2d0.mp4)

The ride went ok, kept the boost really low, only reached 3.5psi and didnt go past 6500rpm which was good as still running on the 750 tune and according to the data log it reached like 18 to 1 a couple of times untill the auto tune fattened the table values a bit. Ive already gone over the datalogs and looked at the trends on the table from what the autotune was doing and manually smoothed the table a bit so should be good to try it again soon, then start feeding in some more boost.
Rode ok otherwise, might add some more preload to the front and back as well. Clutch was good, gearbox is smooth and dosnt jump out of second which was a relief, no real leaks or anything so all in all an ok first trip.
The motor is soooo much more tractable than the 750, just being able to roll on in most gears and it just pulls it, which is great, just need to get that top end back lol

[slingy88]

Well, those video links were crap, so heres some better ones



http://www.youtube.com/watch?v=8YqKVD2q0bg


http://www.youtube.com/watch?v=DKW5xdx0sYQ

[ozzy1100]

More than a few cool fetures aboard ..

[Fight_fan]

How trick is that dash! Awesome work man!

[slingy88]

How trick is that dash! Awesome work man!

Glad you like it :)

Its good to have the datalogger and auto tune onboard, BUT, its already giving me the shits!!!
Went out on it again today, and filmed it but camera angle all wrong so its pretty much an hour of bitumin with a flash of mirror every now and then.

Anyway, HTC kept freezing up, then dropping out, then working etc for the whole ride.It still seemed to autotune and datalog though, even when the dash was frozen.
Also everytime it froze, the push bike speedo which is battery opperated and has no connection whats so ever with the bike would drop to 0. It still showed that it was seeing the signal from the wheel but wouldnt read it. However, when the HTC unfroze, the speedo would work too.

Them Damn gremlins have a lot to answer for in my book !! Must be interference from the ignition or something going on. But couldnt see any corrolation to speed or engine revs or fuck all. So Fuck knows!!
Very tempted to put a mechanical speedo back on it cause i cant be fucked with no speedo. I need also to make some vents in the HTC mount to line up with its fan vents as its getting very hot which isnt probably helping either.

Suppose i'll just keep chipping at it, but just want to ride the bloody thing!

Ohh well, rant over, now, where's those spare carbs............

[slingy88]

Heres a very short bit of film to prove it moves.
At the beginning you can see me starting a log file and then starting the auto tune, ready for the ride, before going back to the full screen Dash .


http://www.youtube.com/watch?v=TSBycEq1bPU

[evad]

Wow, looks great. How is the tuning coming on?

[slingy88]

Wow, looks great. How is the tuning coming on?

Been a bit slow dave. I went for a ride a couple of saturdays ago with a couple of friends up Mt Mee and back. Probably out about 3 hrs.
I was thinking, Great, this will get 80% of my tuning done. But was plagued with lots of little problems.
The first was the on board power supply for the HTC died and as i hadnt had it on charge, it went flat with in 20 mins, so did no tuning or datalogging for the whole ride! I new it was still rich throughout the table so just carried on and rode it as it was.
Then i stopped to get fuel, to find, as i had forgotten ( read as too lazy to do it) to put a tank breather pipe on, it spat fuel out of the breather which rapidly found its way into my crouch.
Then towards the end of the ride, the front brake's started getting really grabby, and even locked up a couple of times pulling up at traffic lights and the such.
So by the time i got home was a bit disgruntalled with it all.
So, i have fixed all the above problems plus looked into the low boost. Found the gasket between the headers and the turbo leaking so replaced that which is now good, and it turns out that this model turbo does have only a 3.5 psi wastegate and the Volvo ECU then raises it from there. Tried adjusting up, setting it with the air compressor, but the amount of boost you have to leak off to get it from 3.5 to 7 or 10 psi is huge. Plus my 2 stage boost controller had packed up. The solenoid valve in it had died, so as i couldnt only run one setting and as i really didnt like having to make such a big boost leak to get it higher i bought and fitted a T28 wastegate acutator which is a 10-30psi unit, so no need to leak boost, just wind up the preload.
So, when i get a chance, i'll take it out and try it.
Interesting though, while i was doing my ride with the HTC flat, the speedo worked perfectly, for the whole ride. So i am thinking, maybe the powersupply for the HTC is creating the interference which is affecting them. Time will tell.

[Redmohawk]

Sounds like the HTC powersupply is putting AC harmonics back into your 12v system, try sticking a diode in line with the HTC power supply on the 12 v side and a capacitor in parallel with the HTC power supply on the 12 v side AFTER the diode. Talk with your local jacar electronics bloke he will most likely be able to show you how to set it up if you cant work it out yourself.

Or I can draw you a diagram if you like. A quick fix would be a isolation choke off an old car stereo (be a box on the red or yellow positive line)

[MattyDucati]

Love what ya doing with this bike bloke. Keep the updates comin!

[evad]

Thats a pity Jack but Im sure you will get it all sorted . I will drop by when I get back mid december real keen to see it in real life and to hear how you are going with autotune.

[Fight_fan]

Glad you like it :)

Its good to have the datalogger and auto tune onboard, BUT, its already giving me the shits!!!
Went out on it again today, and filmed it but camera angle all wrong so its pretty much an hour of bitumin with a flash of mirror every now and then.

Anyway, HTC kept freezing up, then dropping out, then working etc for the whole ride.It still seemed to autotune and datalog though, even when the dash was frozen.
Also everytime it froze, the push bike speedo which is battery opperated and has no connection whats so ever with the bike would drop to 0. It still showed that it was seeing the signal from the wheel but wouldnt read it. However, when the HTC unfroze, the speedo would work too.

Them Damn gremlins have a lot to answer for in my book !! Must be interference from the ignition or something going on. But couldnt see any corrolation to speed or engine revs or fuck all. So Fuck knows!!
Very tempted to put a mechanical speedo back on it cause i cant be fucked with no speedo. I need also to make some vents in the HTC mount to line up with its fan vents as its getting very hot which isnt probably helping either.

Suppose i'll just keep chipping at it, but just want to ride the bloody thing!

Ohh well, rant over, now, where's those spare carbs............

Ahh that sux man! I run a motogatged mini on my 7/11, the speedo hasn't ran right since i had the new loom made up hey! It runs fine up to 100kph but anything over it bounces all over the place my record is 350ish hahaha We thought it might have been picking up interference from the coils but even with wires insulated its still the same… Hope u can sort urs without too much headache!

[slingy88]

Sounds like the HTC powersupply is putting AC harmonics back into your 12v system, try sticking a diode in line with the HTC power supply on the 12 v side and a capacitor in parallel with the HTC power supply on the 12 v side AFTER the diode. Talk with your local jacar electronics bloke he will most likely be able to show you how to set it up if you cant work it out yourself.

Or I can draw you a diagram if you like. A quick fix would be a isolation choke off an old car stereo (be a box on the red or yellow positive line)

Thanks for the ideas man, this is what i have found out so far with it.
The HTC is 12v, and the powersupply is an incar (ciggy lighter) unit for the HTC, with the lighter contacts removed and a short harness soldered in which then connects into the bike loom. From the quick bit of testing that i did and looking at the components in it, it is just a solid state regulator, and already contains shunts and noise suppression, so dont think that is the problem. The spare meter of lead from the supply to the HTC that i have coiled very tightly, (about 35mm across) directly under the HTC and in direct line between the speedo and its pickup however might be a problem. Nice little EMF generater right in the guts of the dash lol.I'll see what effects changing this does as my first action and go from there i think.

[slingy88]

Love what ya doing with this bike bloke. Keep the updates comin!

Will do Matt ;)

[slingy88]

Thats a pity Jack but Im sure you will get it all sorted . I will drop by when I get back mid december real keen to see it in real life and to hear how you are going with autotune.

Yep, not a problem dave, come have a play :D

[slingy88]

Ahh that sux man! I run a motogatged mini on my 7/11, the speedo hasn't ran right since i had the new loom made up hey! It runs fine up to 100kph but anything over it bounces all over the place my record is 350ish hahaha We thought it might have been picking up interference from the coils but even with wires insulated its still the same… Hope u can sort urs without too much headache!

yeah, i'll get it sorted Mr Fan.
Interestingly enough, i got an email from EFI Anylitics, that produce the Tunerstudio software that i run on the HTC, and on the next update they are going to incorporate GPS speedo as an option. Plus supply a 10GHZ GPS usb dongle suitable for any device.
This also opens up a few interesting options. So you can datalog speed as part of the ride info. Very good, but even better is they are going to incorporate Power and Torque gauges into it as well. As, if you know the weight of your bike and put that in to the software, it then nows distance moved (by GPS) over time, thus can work out power. Torque is then just a calculation done off the power figure. So, it deffinately wont be dyno accurate but should be good ball park figure i think. How cool would that be though to datalog everything off the motor and get at the same time datalogs for power and torque!

[slingy88]

Although, as i cant get what i've already got working properly, i dont know why throwing a GPS dongle would be good lol

[Deano]

Although, as i cant get what i've already got working properly, i dont know why throwing a GPS dongle would be good lol

Agreed. What you have seems unreliable at best. No point making it worse.

[slingy88]

OK, a question for all you seasioned oil boiler owners.

Each time i go to take it out for a ride, the clutch is locked solid. ie, it mechanically lifts the pressure plate but the clutch wont release?
I end up putting it in third, and rocking back and fourth with the clutch held in and in the end it gives. Works perfect after that, go for me ride, ride it into the shed, go to move it like a week later and back to the clutch stuck again!!
Last week, i took it apart, and nearly the entire clutch pack came out in mass, with the steels and fibres stuck together. Upon pulling them apart, it looks like its rusted together, with the inprint of each pad of the fibre plate being left on the steels.
I'ver never come across this ever, even on motors that have been in long term storage. A mate who's a motorcycle mechanic hadnt heard of it either. He suggested roughing the steels which i did, then if i had soaked the fibres before fitting. Now, i know you have to soak them before fitting but i couldnt remember if i had or not, so while they were apart i left them soaking 24hrs before putting them back together.
So took it for another quick blast round the block on wednesday, and again, the clutch is stuck!!
They were new EBC fibres, and i am running cheap Castrol Active 4T 15w/50 just to flush through from the motor being apart for so long, so should change it. It is a motorcycle oil and says it protects clucthes etc.
Its hard to tell if its rust pattiner or like a film of clutch fibre material thats on the steels.
Its very uniform throughout the clutch pack and bascially mirrors every contact point that the fibres have on every steel.
Could they be dodgy fibres? Or the oil?
Anyone experianced similar?
After putting it back together all oiled on tuesday, riding it for 15mins wednesday, then have it siezed today, i find it veryhard to believe it could have rusted.

Cheers all

[hyofighter]

can really help you other than I have a similar problem , the trench wench only goes out once a month maybe longer when its in the shed it started every week but never moved till race day first time I put it in gear it stalls the motor like as if the clutch isn't releasing , put in neutral restart is usually fine after that and never faults other than getting a pressure build up over the day of racing and I need to bleed it off , I have ballistic race fibres standard steels and a third diaphragm spring , running penrite tenth tenths oil

[slingy88]

Cheers,

Going to strip and clean the clutch again,then change the oil and see how that goes i think.

Never had problems like this with the 750 and that was left stood for bloody ages sometimes.

[latheboy]

Hmm can't help you with the clutch sorry.... It's your own fault though, if you'd fixed the 750 this would never have happened.

What have you got left of the 750? i might need some bits....

[slingy88]

Hmm can't help you with the clutch sorry.... It's your own fault though, if you'd fixed the 750 this would never have happened.

What have you got left of the 750? i might need some bits....

Mmmmm, that thought has crossed my mind many times in the last 7months or so lol. oh well, i am in no rush so will get there in the end.
Mate, not much of the 750 left, it all sold pretty quick. From memory, side covers, crank, clutchbasket, is about it.
How is yours going?

[latheboy]

Well.......................................




I might be in the market for another motor or rebuild......

150hp at the wheel on 9PSI for a 70K old motor is a big ask i think.

After the last run at the drags there was a bit of a rattle, going to drop the sump and have a look whats in the oil.

[Gix11]

That's a weird one. Never heard of that or had that problem. It would have to be the oil wouldn't it?

[Yella]

Try putting a cable tie around the clutch lever holding the clutch lever in after the next ride see if that helps.

[slingy88]

WOW, been a while since i updated. Not a lot happened really. I got a set of silencers for $1 off that site, fitted them, which i have to say was surprisingly easy. The origional mounts lined up perfect with the old grab handle nutsert, so they actually bolted straight on, bit of a mod to the undertray and panels and a cut of the link pipe and they were on. EASY.
But, i fired it up to have a listen with it on the paddock stand, forgot to take it off the stand , and had it syphon half the contents of the sump into the turbo. BASTARD. So then i made it my mission to stop it from doing this again. So after about 7 different designs and taking the turbo on and off even more times than that, and much watching oil flowing from the turbo drain into a jug and monitoring , i seem to have it all sorted. Its now sporting a modified GPZ fuel pressure regulator as a check valve.
Finally went for a ride. Cant believe how much nicer it is not to have my ears ringing after a ride, and can actually hear the BOV and engine over the exhaust noise. Much nicer.
I also improved the crankcase ventilation making a baffled catch can with a site tube that is plumbed back to the turbo inlet rather than just venting to atmosphere.


http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/DSC_0197_zps9ffcb612.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/DSC_0197_zps9ffcb612.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/DSC_0198_zpsaccb53de.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/DSC_0198_zpsaccb53de.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/DSC_0199_zps47e5f8e1.jpg (http://s557.photobucket.com/user/slingy88/media/750 slingshot/DSC_0199_zps47e5f8e1.jpg.html)

" target="_blank">http://i557.photobucket.com/albums/ss11/slingy88/750 slingshot/DSC_0200_zpsb10c10d6.jpg (http://api.viglink.com/api/click?format=go&jsonp=vglnk_jsonp_14096520699066&key=bbb516d91daee20498798694a42dd559&libId=e4a8573d-1e14-41c5-839d-6b0f7feaf0a2&loc=http%3A%2F%2Fold-skool-suzuki.proboards.com%2Fthread%2F2407%2Fgsxr-7-11-tiefi-mus2%3Fpage%3D1%23scrollTo%3D17075&v=1&out=http%3A%2F%2Fs557.photobucket.com%2Fuser%2Fsli ngy88%2Fmedia%2F750 slingshot%2FDSC_0200_zpsb10c10d6.jpg.html&ref=http%3A%2F%2Fold-skool-suzuki.proboards.com%2Fpost%2Fnew%2F2407&title=GSXR 7%2F11 TIEFI MuS2 | OSS&txt=<IMG style%3D)

[Gix11]

VFR cans? Is that a second set of side covers you adapted to fit the can snuggly or your one-and-onlys?

[slingy88]

Yep, factory vfr stainless cans, and yep my one and only plastics cut to fit, although the fit on the right side ( first one I cut) is not as neat as the other, so am on the hunt for another to cut up. Think it needs some moulding between the top of the can and the plastic as it has a bit of a funny transition angle.

[evad]

Looking good Jack, nice job

[slingy88]

Ok, my smoking issues still arnt solved !!!

But i have found a culprit that isnt the turbo .

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/DSC_0217_zps8d687927.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/DSC_0217_zps8d687927.jpg.html)

http://i557.photobucket.com/albums/ss11/slingy88/750%20slingshot/DSC_0213_zps169c1b83.jpg (http://s557.photobucket.com/user/slingy88/media/750%20slingshot/DSC_0213_zps169c1b83.jpg.html)

2 leaking stem seals. The second picture is pretty bad. Thats just from 1 night standing.

Typical, the only job i didnt do while putting the motor together was................Skimming the head and fitting the brand new OEM Suzuki valve stem seals so i didnt have have any future issues!!!!!
I was always a bit dubious as the head shop rang me after a couple of days to say they had fucked one of the seals, tryed to put one of the old ones on ,but wasnt happy with it . NO SHIT. So could i get them another seal.
Which i did, but dosnt surprise me now that others have failed. Probably tore them putting them in or something.
Oh well, lesson learnt. And they wont be getting any more trade or recomendations from me.

[Yella]

That sucks

[slingy88]

Mmmmm.....does indeed. I am gonna try changing without taking the head off. I take some photos and stuff of how I go.
Plus, I am going to have a go at making an emtes style mechanical scavange pump as not that happy with the electric scavange pump setup.
Again, plan on covering this fairly indepth for others to follow.

[Redmohawk]

Air compressor and a air fitting brazed into a spark plug with the ceramic smashed out. Air in to hold valves out pop off retainer , spring swap out seal replace and next please !

[Tony Nitrous]

Air compressor and a air fitting brazed into a spark plug with the ceramic smashed out. Air in to hold valves out pop off retainer , spring swap out seal replace and next please !

Never done it myself but mate recons that's how they put ZZR cams and springs into ZRX's.

[slingy88]

Air compressor and a air fitting brazed into a spark plug with the ceramic smashed out. Air in to hold valves out pop off retainer , spring swap out seal replace and next please !

Yep, that's exactly how I was thinking of doing it. I was going to see if I could use the fittings from my compression tester, but no biggie if I have to make something.

[Yella]

Works a treat I got a kit with a multifit hose adapter and spring tool for about $50 can you get the rocker cover off in frame ?

[slingy88]

Works a treat I got a kit with a multifit hose adapter and spring tool for about $50 can you get the rocker cover off in frame ?

A good question! I did build the top end in the frame. But to get the cam cover on, I had to slide it up and over from the back of the head, so it will have to come out the same way, so will have to take the TB 's off to get the cover off.

[latheboy]

Mmmmm.....does indeed. I am gonna try changing without taking the head off. I take some photos and stuff of how I go.
Plus, I am going to have a go at making an emtes style mechanical scavange pump as not that happy with the electric scavange pump setup.
Again, plan on covering this fairly indepth for others to follow.

I made my own scav pump.

http://i1226.photobucket.com/albums/ee405/latheboy179/IMAG0011.jpg

shitty pic but you get the idea.

It's a oil pump off some china shit box scooter that i made a housing for.
Drives off the SHCS on the crank.

I could send you the drawings if you like.

[latheboy]

Oh yeah, don't do drunkun skids and lay it over on that side :)

Gotta made a slider for it haha