Saturday, 2 December 2017

TB's stripped

Stripped the GSXR Throttle bodies and the inlets fit the original carb rubbers.


think I'll take off the secondary butterflies as 1 is not there anyway.

Its something the suzuki boys do anyway.

I can then hopefully tap the holes and fit air flow sensors for the Microsquirt input.
TPS is separate from this and is needed.

I also need to setup a crank sensor with 2 TDC's as its a 180 crank. MS will sense the VR through the gaps in the tooted crank wheel. I may locate this on the righe pinion which connects to the clutch basket

Saturday, 25 November 2017

GSX-r 600 TB's

these have arrived and the inlet side fits the original inlet rubbers

these split apart and I am going to use the 2 outer ones for the TPS and cable hook up.

the cold start will only work the left hand TB but peeps have taken these out completly but struggle with cold starting. As mine is kick start only, I need all the help I can get. I may even have to bump start it, we'll see


Sunday, 19 November 2017

Its not over

Sorry its been a while, I bought another bike to travel spain and so took all my money and time up.

So I've spoken to a contact regarding supercharging and because of the 180' crank there are issues with balance of the intakes and he recommend I use FI withthe super charger.

I've just purchased a GSXR600 throttle bodies and mini loom and will disect these to go on the inlet. These bodies are early K1 -3 and have separate bodies so easier to separate and make up  the correct distance.

Along with this I'm getting micro squirt to manage ignition and the injectors whilst making use of the TPS and Idle sensor.

still a slow burn project as the wife wants a new bathroom

Specs;
Make/Model: GSXR600
Year: -02
Number of Tb: 4
Inside Diameter: 38mm
Center-Center (left to right from behind): 80-80-80mm
Overall Length: 83mm
Outside Diameter (intake): 44mm
Outside Diameter (filter): 45mm
Separate casting: Yes
Injector Make/Model: Keihin KN4, 0J07 AAA A
Flow Rate (45psi/100%): 240cc/min?, 13?
Fuel Rail: Alu casted, Inside diameter 6mm (9mm in the ends)
Additional Info: sec. throttles controlled by ECU.

Tuesday, 19 July 2016

This is going to be a back burner project as this has never been done before on an XS400. I've decided to try another approach to fitting the charger and this seems to fit (just)



I may get away with a 90mm pulley system which will make the crank fitment a little easier. It will aslo facillitate the jockey wheel and leave enough space for the belt to be pinched. the fuel will enter the top aprt and exit from the bottom Mount/ manifold. not sure whether to have 2 out lets either side (which looks good)or go for a single side to plennum chamber

Monday, 16 May 2016

supercharger mount

A bit more work on mounting the supercharger

checking gaps, belt route, pulley size (prob 60mm 1:1 ratio)


only 50mm gap between the SC and the head, so its an up and over tube arrangment

whilst changing over the fill casting, the last person ommitted to fit a nut on the lobe gears

its a strange size, 14mm x 1mm thread very fine



managed to weld a temporary mount together in steel just to see what fits where etc etc.

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]
managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]
think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.
up and over 1.5" tube to the inlets .
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]
there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]
whilst changing over the oil fill casting, I noticed a nut missing off one of the gears
[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

Saturday, 23 April 2016

Got the GS500 liners machined today so they will fit into the barrel and case of the bike

Monday, 18 April 2016

new pistons

Decidied that the GPZ900 pistons will have too high a compression so I've done some digging and come up with Honda transalp pistons at 74mm.

just bought  some GS500E cylinder liners and had them machined OD 81mm and will get them fitted to an enlarged cyl and crank mouth.

I have also got  another engine so if it goes pear shaped, I have a back-up