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from memory the stock base gaskets are .5mm and have some kind of silicone or rubber coating. just use a few of them and because they have the coating there no need for sealant. My 2mm spacer was made from aluminium. i clamped it between 2 pieces of mdf, drilled the holes and then just cut it with a jigsaw. bit af i file to tidy up and was done.
who does everyone get piston, gasket etc sets from anyone OS that any good and a good price
I get my aluminium base spacers laser cut now but did a lot by hand out of copper originally, jigsaw and drill too .laser is much easier ;) if your base spacers are .5mm just get a few and stack them , one old and 2 new each side will do it the suzuki ones are .25mm ,
Simple buying OS , aftermarket.. Orient Express, and oem... partshark , both have online stores, express post and are reasonable in there pricing , partshark will take longer as they order in after you order, Orient usually have good stock and will let you know if there out of stock
if you do buy pistons, make sure they DON,T have XA type oil rings. they are fucked in every way. I spent $3000 on a zx9 motor only to have it go bang because of these pieces of shit. i was warned but stupidly chose to try em anyway. they say learn from your mistakes... so you can learn from mine.
Got some time today stockbase gaskets are .20mm so I either stack 6 together or I find something to make a spacer out of :D
Bores cleaned up OK, head seems to check out so I will order some bits get it back together and see if I can blow it up :D
http://pic70.picturetrail.com/VOL183.../397535919.jpg
http://pic70.picturetrail.com/VOL183.../397535914.jpg
I like to try and support local guy's if it is not going to kill me with high cost/bad service ETC so I did a bit of looking at cost over the interweb and a couple of local calls last week.
Most of the local dealers are well above the O/S cost but Flywheels at Alexandria seem to be on the money again(they alway seem to be well below every other Kawasaki dealer ?? makes me wonder about the rest) and I will not save much if any after I factor in freight so I will double check tomorrow when I have some time and if correct will place my order :D. Bit of a trip to get in to Alexandria from Western SkidaKnee but ya get that and last time I was in the area I seen a white unit with an ASF sticker on the back window so I feel at home [8D][8D].I will talk to them about dyno time aswell ya never know
I get a few things of flywheels also, they use Fastway couriers and most items get delivered for about ten bucks extra. A much better option then fighting the Sydney traffic.
Looking at getting a spacer plate cut out of stainless what is the going rate. The people I have spoken to are talking $100 give or take to supply materials and cut
If you know someone who uses a CAD program get them to draw it up, then send the DXF to the cutters. It'll be cheaper that way because the cutter wont have to draw it from scatch.
And NO sharp corners anywhere only radi.
They do a CAD and convert to DXF as part of the price. Sadly don't know anyone that can do it other than them
Really truth be told i think thats a good price for the work thats to be done.
As a paying job i'd change that before laser cutting, thats why i said get a mate cause mates are free :D
Converting to DXF is a mater of clicking the mouse a couple of times so don't be fooled that it's hard work, the time is in drawing the part.
Why stainless ?? aluminium or copper are so much easier to work
+1 for Alooominium.....;)
oh & as it's a base spacer you could cut it by hand pretty easily.
Was thinking about that but I want to get a couple of other bits done ( want to make a new plenum and carb plate)so may get it all done together.
Ben I will give you a call Monday and see what you can do [8D]
Does anyone know what size jets come in the dyno jet stage 1 kit or am I better off having just getting a some straight from kawasaki? Looking at about 150 - 160 main
You shouldn't have to go that big if you have good dynamic boost. Shouldn't have to go much bigger than STD jets
Standard is 200(1 & 4) 210 (2 & 3) going by the manual. Will pull them down again tomorrow and check I think mine has 180 & 190 (can not remember exactly)
The fella I was speaking with is running 150 in all 4 on his turbo zx7 and he is happy and seems to be running clean.
Struggling with this a bit but will work through it
Kawaka jets must have different number system to Suzuki. A 750 suzuki would be about 117.5 mains
As you were
bugger if I know found this,
(Width = true hole diameter)
Width------Keihin # -- DynoJets # -- Mikuni #
0.0350---- 92.5--------- 92---------- 86.3
0.0360---- 95----------- 94---------- 88.1
0.0370---- 97.5--------- 96---------- 90.0
0.0380---- 100---------- 98---------- 91.9
0.0390---- 102.5------- 100---------- 93.8
0.0400---- 105--------- 102---------- 95.6
0.0410---- 107.5------- 104---------- 97.5
0.0420---- 110--------- 106---------- 99.4
0.0430---- 112.5------- 108--------- 101.3
0.0440---- 115--------- 110--------- 103.1
0.0450---- 117.5------- 112--------- 105.0
0.0460---- 120--------- 114--------- 106.9
0.0470---- 122.5------- 116--------- 108.8
0.0480---- 125--------- 118--------- 110.6
0.0490---- 127.5------- 120--------- 112.5
0.0500---- 130--------- 122--------- 114.4
0.0510---- 132.5------- 124--------- 116.3
0.0520---- 135--------- 126--------- 118.1
0.0530---- 137.5------- 128--------- 120.0
0.0540---- 140--------- 130--------- 121.9
0.0550---- 142.5------- 132--------- 123.8
0.0560---- 145--------- 134--------- 125.6
0.0570---- 147.5------- 136--------- 127.5
0.0580---- 150--------- 138--------- 129.4
0.0590---- 152.5------- 140--------- 131.3
0.0600---- 155--------- 142--------- 133.1
0.0610---- 157.5------- 144--------- 135.0
0.0620---- 160--------- 146--------- 136.9
0.0630---- 162.5------- 148--------- 138.8
0.0640---- 165--------- 150--------- 140.6
0.0650---- 167.5------- 152--------- 142.5
0.0660---- 170--------- 154--------- 144.4
0.0670---- 172.5------- 156--------- 146.3
0.0680---- 175--------- 158--------- 148.1
0.0690---- 177.5------- 160--------- 150.0
0.0700---- 180--------- 162--------- 151.9
0.0710---- 182.5------- 164--------- 153.8
0.0720---- 185--------- 166--------- 155.6
0.0730---- 187.5------- 168--------- 157.5
0.0740---- 190--------- 170--------- 159.4
0.0750---- 192.5------- 172--------- 161.3
0.0760---- 195--------- 174--------- 163.1
0.0770---- 197.5------- 176--------- 165.0
0.0780---- 200--------- 178--------- 166.9
0.0790---- 202.5------- 180--------- 168.8
0.0800---- 205--------- 182--------- 170.6
0.0810---- 207.5------- 184--------- 172.5
0.0820---- 210--------- 186--------- 174.4
0.0830---- 212.5------- 188--------- 176.3
0.0840---- 215--------- 190--------- 178.1
0.0850---- 217.5------- 192--------- 180.0
0.0860---- 220--------- 194--------- 181.9
0.0870---- 222.5------- 196--------- 183.7
0.0880---- 225--------- 198--------- 185.6
0.0890---- 227.5------- 200--------- 187.5
Keep this in mind---> From a Dynojet tech rep:
We are often asked for a "cross reference" sheet that compares our main jets to Mikuni or Keihin. The fact is you cannot directly interchange the jets for a given size. Many things affect fuel flow through a jet of the same orifice size. The entry and exit tapers of our main jets differ from those of other companies. Due to this, the fuel flow changes as a function of velocity through the carburetor venture. This means that two jets of equal orifice size will have a different fuel flow curve relative to intake air speed. At a certain speed the two may flow equally, but a change in velocity changes the flow characteristics. The Dynojet main jet hole size is measured in millimeters. For example, a DJ142 has a 1.42mm hole.
Michael Cory
Research & Development
Phone: 800-992-4993 EXT. xxx
Michael@Dynojet
The satge 1 dyno jet kit includes,
Fuel - 1998 Kawasaki NINJA ZX-7R(ZX750P3)US
Note: Includes 2 Main Jet DJ132, 2 Main Jet DJ134, 2 Main Jet DJ136, 2 Main Jet DJ138, 4 Fuel Needle DNO119, 4 Main Air Plugs DCO200, 4 Slide Springs DSP006, 4 E-Clips DE0001, 8 Adjusting Washers DW0001, 1 Plug Drill DD #5/32, 1 Screw DS0001, 1 Slide Drill DD #
And everythng I am reading is telling me the ZX7 has large main jets to help with the factory emissions system once remove you go smaller and with the turbo Im thinking smaller is the go
Put in some new plugs before you start it again and keep an eye on them for det sign and lean.
Get an AFR metre of some sort too.
Your better off being rich than lean....
My first turbo bike i tuned with a jaycar narrow band o2 sensor and led display, on boost it had to read rich but not be bogging down and it was fine ...if it read normal or lean it was too lean , and black smoke or bogging down was too rich ,
I have heard alot that dj or factory pro needles needles are no good for turbo.
What Ivan said. You really need to know what the afr is doing before you ride it cause it will go bad before you know it if it hasn't already
I have heard the same about the needles. Will probably just get Kawasaki jets in the size I need. I am still going to run 2 different sizes as per factory
I was thinking of running the CR9EK plugs instead of the standard CR9E ( The K is the dual electrode) anyone tried this any advantage?
Will be getting hold of an AFR gauge soon hope to have it before I bolt it all back in
You can fine tune needles with a bit of fine wet/dry, crc and a drill
Ok so I ened up ordering bits from Part Shark as it worked out a heap cheaper after speaking witha couple of local shops. All bits arrived super quick so happy as. Went out ans spoke to the water jet fella and he is cutting a base spacer for me for $40 figured I can't go wrong :)also spoken to him about cutting a new air box base plate out of alloy. It will make life easier and seal better so he is making for me aswell. Once the motor gets a paint and put back in I will makea in plenum to bolt to it with intercooler and start again with the tune ad set up.
$40 for the base gasket is a bargain mate. i'll look forward to seeing this bike up and running. if you're anything like me, you won't sleep properly until it is.
it's gone quiet!! where are you up to?
Waiting on parts and time hope to get back to it this week
Thinking of painting the engine black while it is out. What do you guy's think?
What is te best paint to use?
2 pack solid i can do it for you depends how keen you are i have paint otherwise vht engine paint can also paint bits body colour if you want to just yell out if you need em done.
I purchased 2 cheap (read really cheap) digital guages from egay 1 boost and 1 oil pressure that i will use for fuel pressure. They arrived a while back the boost gauge worked sweet but the oil gauge did not read correct the display was faulty. Anyway sent them a message an after a bit of back and forth they sent me a new gauge tested today all seems good.So I got the old gauge and wired it up again still the same so i gave it a bit of the knock on the bench and fuck me it works. So I gave it a couple of good belts and it is still working as good as the new one :D now I have 2 sweet.
Still waiting for bits.............................................. ............... this is killing me
We have some action. Picked upthe base spacer today
http://i1234.photobucket.com/albums/...3082011593.jpg
We took the rubber boot off to have a look at it..... nice
http://i1234.photobucket.com/albums/...3082011594.jpg
Some shots of it being cut but in my rush to get it back together forgot to take a pick of the finish item.
So new rings in and head torqued down now time to hit the piss and party for tonight and back into it tomorrow guessing with a hang over but motor should be bolted back in and having a test fire up by the arvo........ SWEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEET
That's fucking cool
I've been watching this for a while..... nice work mate. [8D]
So the motor is back in heavy fucker on me own but got it done. no pic's of that but
http://pic100.picturetrail.com/VOL69.../398088920.jpg
fitted the new front guard from the earlier 7 ( thanks PAV) while I waited now just need to get it back to Pav for paint along with the rest of the bits as I think a slight color change is gunna happen, but dont worry it's still going to be yellow ( haters gunna hate ) just a bit different to now:D:D
cool. i'd like one of those water cutters in the garage.
guard looks like it was meant to be there mate now get it running and drop off the bodywork and ill sort it out.
Heaps going on just not alot on the bike hope to get back into it tomorrow. Hugger arrived and some other bits so will get some pic's tomorrow and post up. Need to pull the finger out