SuzukiHayabusa.org
MEMBERS => MEMBER PROJECTS => Topic started by: jgennaro on May 22, 2010, 09:20:48 AM
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I started working on my turbo street bike in February and it's taking forever! :cry:
Hopefully when it's done it will be worth the wait and stress.
A few pics:
My first time measuring head and piston volume. The head ended up being 19cc and the JE turbo pistons were 17cc.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1604.jpg)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1617.jpg)
Falicon crank work and Crower refurbished rods
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1621.jpg)
Clean cases......which were a pain in the ass to clean!
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1622.jpg)
Bottom end with windage tray by Falicon, ARP main studs, and ARP case bolts from Heads Up Performance.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1626.jpg)
Bottom end together
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1627.jpg)
JE turbo pistons and ARP head studs in
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1637.jpg)
Top end together minus the cam chain. Mine is too short. :cry:
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1639.jpg)
A lot more to go! At this rate I'll be lucky to finish by December!
Jason
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Looking good Jason :thumb: :thumb: :thumb:
Mikey
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:thumb:
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:thumb:
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Nice stuff!
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You got it! Don't lose hope! Focus on what the end product will look and sound like :) That'll keep you going :thumb:
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nice, looks good..... :thumb:
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A little work to the swingarm to make it a reservoir for the heat exchanger.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1640.jpg)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1643.jpg)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1642.jpg)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1641.jpg)
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i like that your using the stock swingarm for a heat exchanger! looks very good! :thumb: i will have to stay updated on this to see how well it works. good luck with it.
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i like that your using the stock swingarm for a heat exchanger! looks very good! :thumb: i will have to stay updated on this to see how well it works. good luck with it.
Actually, I'm going to have a heat exchanger in the ram air tubes and the swingarm will hold additional water. :thumb:
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Cam timing.......I don't want to do that again!
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1661.jpg)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1663.jpg)
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Yup, cam timing is a punishment :lol:
Engine looks good :thumb:
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:ppcrn:
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Motor is in and plenum is on. Boy that RCC stuff fits and looks great!
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1664.jpg)
The fabricator is finishing the heat exchangers so I'm hoping to get some more work done this weekend.
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Sweet :thumb:
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Looking good Jason!! :thumb:
Can't wait to see the numbers... :thumb:
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well now, thats some pretty stuff right there haha
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Ultra heat exchangers
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1709.jpg)
Ultra heat exchangers with front fairing on(turn signals are taken out)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1706.jpg)
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Looks good....are you running the aftermarket fuel rail AND secondaries in the plenum? I assume you are using a microtech for the plenum secondaries?
Cool work on the heat exchangers. You probably won't need the water reservoir in the arm with those for street use.
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Looks good....are you running the aftermarket fuel rail AND secondaries in the plenum? I assume you are using a microtech for the plenum secondaries?
Cool work on the heat exchangers. You probably won't need the water reservoir in the arm with those for street use.
I'm running the 650cc injectors as my secondaries and hopefully ecueditor. The stock ones are just in the fuel rail not hooked up to power.
I was going to use smaller heat exchangers so that's why I used the arm for more water. I'm thinking since it's already there I'll might as well use it for more water in the system. It's one of those can't hurt might help scenarios.
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Looking good Jason :thumb:
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looking good! Send those rearsets off to get PC'd black while you are building the rest of the bike :thumb:
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looking good! Send those rearsets off to get PC'd black while you are building the rest of the bike :thumb:
:thumb:
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where can you order those heat exchangers??
ps. great project
greets
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where can you order those heat exchangers??
ps. great project
greets
They're dirt bike radiators which were fabricated to fit. If you want I can give you the guys contact information who made them for me. I send you a PM.
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THANKS....
i am ordering parts and will builmd a turbo bike next year in wintertime....
thanks IIIII want thosee yihaaaaa
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Looks sweet Jason. Love the twin heat exchangers.
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Great looking build! :thumb: :thumb: :thumb:
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Looks good broski...Hopefully we will ride out someday :)
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Need an update, with pix 8)
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You're right Tom I've been slacking!
Here's another pic of the exchangers mounted with water hoses attached.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1712.jpg)
L side with up pipe and stuff on.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1711.jpg)
R. side with oil lines, some fuel lines, oil cooler, exhaust, and scavange pump on.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1710.jpg)
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And the water pump set-up.
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1713.jpg)
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:thumb: :thumb: :thumb:
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Looks sweet Jason. Love the twin heat exchangers.
Those things are way cool! :thumb:
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who did refurbish those crower rods??????
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and can you use those exchanger as air to air???
how do u no that those exchanger are big enough????
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who did refurbish those crower rods??????
Sent them back to Crower in Cali.
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and can you use those exchanger as air to air???
how do u no that those exchanger are big enough????
Air/air.....no.
I know their big enough because they're the same size as the one that fits in front of the radiator on Richards kit.
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Thanks for the link.
this looks great. :thumb:
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That project looks sweet Jason :thumb:
Amazing job :thumb: :thumb: :thumb:
Mikey
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Very nice! :thumb:
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LOOKS LIKE A FUN PROJECT... :thumb:
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:thumb:
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Nice. :D
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LQQks great ! I'm a dump pipe man, but it's still a very nice job.
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looking good! Send those rearsets off to get PC'd black while you are building the rest of the bike :thumb:
I just happen to know a guy for that... :wink:
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Ultra heat exchangers
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1709.jpg)
Ultra heat exchangers with front fairing on(turn signals are taken out)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1706.jpg)
Bad Ass
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Damn Looking good!
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See you soon :thumb:
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Hey Jason. Any progress since your last update?
How you been, btw?
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Hey Jason. Any progress since your last update?
How you been, btw?
Lot's of progress. I just haven't had time to post about it. I'll take some pics tomorrow and finish up this post next week with the latest and greatest.
I've been great. The wife, family, and work is wonderful and in our economy I'm lucky to have a job. Speaking of the job I got accepted to the EFOP at NFA last year. I've got three more years left and I'm done........way done!
Jason
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Very nice job Jason :tu:
I love the exchanger location 8)
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OK......it's been some time since I've updated this thread. I think the motor went in the bike in October 2010 and I started it in November. I've had quite a few problems which I think is typical with a turbo bike. The cheap ass stainless lines that I used for fuel and oil had to go because they leaked everywhere. I had a few fuel leaks which were solved with new o-rings for the injectors and threadlock on the fuel rail fittings. I also had a bad injector. Lucky for me when I first started the bike ECU editor gave me the primary injector #4 code and I fixed it from there. I had a hard time believing that a bike with 2K miles would have a bad injector but sure enough that's what it was. I followed the instructions in the manual regarding that code and what to check with the multi-meter. After the injector issue was resolved it by replacing it the bike ran like a champ! :lol: :thumb:
I did a few heat cycles on the bike around town and changed the oil to prepare it for some dyno time. Bill Warner was nice enough to invite me down for dyno time/lessons. I think I brought the bike down four times and made like 60-70 runs. Bill was an awesome teacher. He showed me the basics of dyno tuning with TPS maps and boost maps. In addition, he helped me do quite a bit of trouble shooting. As mentioned earlier turbo bikes have lots of issues/problems, Bill found several problems when the bike was on the dyno such as a loose crank trigger wire which caused the bike to fall out past 7K RPM, a blown fuel pump fuse which didn't allow the bike to start, and a few other things I can't remember.
The dyno days were fun and I learned a lot. This was my first time tuning with gen II ECU Editor so there was a huge learning curve. It was huge because the hardware and software was new to me and also I'm not an experienced motorcycle tuner. I researched how to use ECU Editor and whatnot but as you guys know it's one thing to read up on something but it's completely different to implement it and do the hands on learning. Once the gremlins were taken care of and the software was understood it was smooth sailing. The IAP and TPS maps were tuned and it was time for boost tuning. The great thing about boost tuning was that I had Bill there to guide me because I was a little nervous. The last thing I wanted was for 10 months of building and fabricating to go down the drain. Bill guided me tuning the boost map using spring pressure and explained the coorelation from that spring pressure map to the rest of the boost table. After spring pressure was tuned Bill had to leave and I was on my own. It was just me, the dyno, and the dogs. I followed Bill's instructions and in a few hours the bike was fully tuned to 15 pounds of boost. :D :D :D :D :D :tu:
A tuned bike with boost was a wonderful Christmas present! I cut up the fairings to fit and I've been trying to get use to the bike ever since. I think I've been out on it five or six times in the last few weeks and I have two words........bad ass! The gen II is very smooth and has lots of power. As a matter of fact it has so much power it's wheelie prone in first, second, third, and fourth gear. First through third are wicked violent wheelies. Fourth is a little more controlled. I'm still not use to the stock wheelbase turbo bike but I think in a month or so I'll be a little more confident. The bike starts boosting at 3800RPM's at 15 pounds and 4500RPM at 8 pounds so throttle control is a little tricky especially around sweeping curves.
I really enjoyed the project and I'm thankful I've had help from board members and sponsors. Thanks guys!
Bill Warner................................dyno jedi and tuning master helped me extensively with tuning
Richard at RCC.......built the ultra plenum, motor building advice, ECU Editor advice, and a butt load of other stuff
Greg Smith......built a bunch of ECU Editor related things, tech support for tuning, and various Busa parts
John Bullock........I modeled my bike from his and he helped with various things on the bike
Sportbikeryder John.....I got LOT'S of engine building advice from him
Jason
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what kind of hp did you get with 15 pounds of boost.what size turbo
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The turbo is an McXpress 58/12 twin flow. If I rember correctly spring pressure at 8.1 pounds of boost was 255 RWHP and 14.8 pounds of boost was 342 RWHP. I'm at work so I don't know if I can find my datalogs and dyno runs. I'll take a look later.
Jason
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I forgot I have my laptop here today. :tu:
Here's the log with ECU Editor at 14.8 pounds of boost:
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/lastlogat148poundsofboost.jpg)
The dyno sheet from that run:
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/2008mcxpresshpandtorque.jpg)
Jason
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The dyno sheet looks nice Jason :tu:
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The dyno sheet looks nice Jason :tu:
Thank you. I think there was a little wheel slip there over 10.5 RPM but other than that it's pretty good for pump fuel at 15 pounds on the street.
Jason
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The dyno sheet looks nice Jason :tu:
Thanks you. I think there was a little wheel slip there over 10.5 RPM but other than that it's pretty good for pump fuel at 15 pounds on the street.
Jason
Very good result with pump piss :tu:
I think you will have much more wheel slip when you are on the street with your bike :mrgreen: :bike:
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Very Nice!
I left they were just talking about the ecu's and starting to hack them..
Now everyone can hack n tune them --- nice :tu:
I have a lot of catching up to do... :bike: :lol:
Great Job in the Bike Jason 8)
Ron
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Nice job Jason! 340+ on pump gas.... :shock: :thumb:
Did yall ever turn it up and make the "real" pulls?
You had the best tuning for you, thats for sure....
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Alan :bah:
man I been gone too long... but running around again on the boosta, need to get to the cheeseman for tuning by months end..
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get the Oil Pump situation figured out Jason?
I wound up Gutting my MCXpump and running the cycle-tech one, and plugging the vent line off of the catchcan on the turbo.
Works like a charm with the two .060's
How is yours doing Jason?
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Alan :bah:
man I been gone too long... but running around again on the boosta, need to get to the cheeseman for tuning by months end..
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get the Oil Pump situation figured out Jason?
I wound up Gutting my MCXpump and running the cycle-tech one, and plugging the vent line off of the catchcan on the turbo.
Works like a charm with the two .060's
How is yours doing Jason?
Good to see you back Ron! Glad you FINALLY got your bike running again...Its only been like 5 yrs....
BTW I got an old school now myself..... 91' Team Hammer/Valvoline Suzuki GSXR750 road race bike......Its fun....slow, but fun. :D
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Alan :bah:
man I been gone too long... but running around again on the boosta, need to get to the cheeseman for tuning by months end..
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get the Oil Pump situation figured out Jason?
I wound up Gutting my MCXpump and running the cycle-tech one, and plugging the vent line off of the catchcan on the turbo.
Works like a charm with the two .060's
How is yours doing Jason?
Ron,
I did some research on it and what I neded up doing was tapping a 3/8" NPT additional vent from my crankcase and T'ing that into my vent line. Basically when my catch can overflows it dumps it into the top of the crankcase breather.
Thus far it's worked well. I'll see if I can get some pics of it. :tu:
Jason
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Nice job Jason! 340+ on pump gas.... :shock: :thumb:
Did yall ever turn it up and make the "real" pulls?
You had the best tuning for you, thats for sure....
Alan,
It's just a street bike so there is no need to run the boost up real high. That 15 pound run is the highest I've had it at. I guess I could turn it up to 18 pounds on pump fuel and see what it puts out. I would guess 370'ish.......but that's just a guess.
Jason
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Alan I know man insane but I am extremely happy to be Boosting again :tu:
Going to have to make a trip to the Kill Country soon, working on a group off another board, if you're interested will keep you informed when we have a date.
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Ya Jason do that please, would make me feel SOOO much better then just the solution I am working with.. ince the new pump faisl atleast it will go somewhere other then my arm or the bike somewhere else...
I have the busa in the kitchen so I can do it while the snow/ice storm is down here..
Thanks!
Ron
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Real cool project, well done. Love the duel heat exchangers in the fairing.
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great project J :thumb:
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Very nice bike.
One asks where I can buy the boost compensate clutch?
Thanks.
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Very nice bike.
One asks where I can buy the boost compensate clutch?
Thanks.
Andersson turbo.....in Sweden
You can probably contact him here:
http://www.turbo-bike.com/Andersson%20turbo%20Hayabusa.html
Jason
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I to send an e-mail days ago but I have not received answer. :cry:
Thanks Jason.
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Kool build and nice work!! :thumb: :thumb:
all that HP and a stock arm!!! Your a brave man!!
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Kool build and nice work!! :thumb: :thumb:
all that HP and a stock arm!!! Your a brave man!!
I thought about changing it but Terry at Mcintosh said it was fine for my HP and torque. It's been about a year now and it hasn't folded or bent on me so I guess it's good.
Jason
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Ultra heat exchangers
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1709.jpg)
Ultra heat exchangers with front fairing on(turn signals are taken out)
(http://i47.photobucket.com/albums/f154/jgennaro/2008hayabusa%20project/100_1706.jpg)
:thumb: :thumb: :thumb:
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Killer :tu: