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

Friday, 19 February 2016

New Con rods and GPZ pistons

Bernd on  xs400.net in Germany have found that XJR1300 conrods fit the XS crank.

He also used GPZ900 standard pistons, whilst  at 72.5mm, still ok to bore out the barrel to that size.


 the bearing shells of the XJR.
XS .............. => XJR
1L9-11656-00 => 36Y-11656-00
1L9-11656-10 => 36Y-11656-10
1L9-11656-20 => 36Y-11656-20
1L9-11656-30 => 36Y-11656-30

The pistons need to be modified on a milling machine and new valve cut outs made for the XS valves

 The only issue is that they are 1mm too high.


Sunday, 10 January 2016

SU carb

Today I started collecting parts for the build.

SU 1 1/4" H2 rebuilt

this mounts at an angle which hopefully will pair up with the angle of the charger.

Need to think about pipe work and mounting the blower.

For this I have made some mounting templates out of card and when I get the tracker MOT'd (as its due) and the FZ600 back up and running, I'll take the bike off the road.