hybrids YZR500 project

[hybrid]

Finished the right hand side throttle bodies and manifolds today.
I will have to use small foam filters like the mad beaver kit uses as there will not be much room when the fairing is on.
Considering these throttle bodies cost me the postage from US to AUS, they were an absolute bargain. They come complete with TPS, so I can use one TPS for my injection computer and the other TPS for the Zeeltronic CDI-024

[hybrid]

Been a long time since an update, but thats because nothing major has been done. I've just been doing a lot of fiddly stuff thats frustrating.

Heres the current pic taken tonight:


I've been slowly doing some work over the last month when I have had time.

Some of the items of note:
- Mounted YPVS controller in the front of the fairing
- Raised the radiator higher to give better clearance from front tyre and bottom plugs
- Modified the cable from YPVS controller to oil pump to reach the new YPVS controller location
- Modifed the top triple clamp and ignition switch to fit the standard RZ500 ignition switch
- Fabricated a plate to go above the engine to mount the battery. This will also mount the fuel pump and other items.
- Put some transmission oil (1.6L) in the bike

Whats next?
There is still plenty to do before its ready to fire up, such as:
- Make fuel rails
- Mount ECU, Zeeltronic ignition components etc
- Find a fuel pump seeing as the GPZ1100 pump seized while it sat around doing nothing for a year
- Start the wiring

Its certainly not going to be ready for Phillip Island MotoGP in October like I had hoped.

[hybrid]

Just another quick update.
I'm in the new place now.. I have a nice big garage which is much cleaner than the old one.
I have my 3 bikes and 2 cars in the garage.

I have not built a work bench yet though, so I'm restricted with what I'm able to do.
Tonight though, I picked apart the wiring harness because I'm moving several parts around the bike.
I also found a fuel pump that is supposed to be fairly low current draw, so hopefully it does the trick.

Anyone for spaghetti?

[hybrid]

Well another small step last night.

I hooked up the power to the Microsquirt ECU and connected the tach output from the zeeltronic to the Microsquirt.

I kicked the bike over and Megatune flashed to cranking and showed some RPM.

I have decided to redo the manifold rubbers, so when I can try and start it will depend on when I get the replacement rubbers.

I'm still hoping that I can try this weekend though.
I have no coolant lines hooked up yet though, so its going to have to be a quick test.

[hybrid]

Well lads, she made some noise!

Earlier today I hooked up the ignition and sprayed some fuel in the throttle bodies. It fired, so I was inspired. And that rhymes.

Anyway, I decided I would quickly hook up some fuel lines to the fuel pump and sit the tank on just for shits and giggles.

Well blow me down.. the thing started!
I have all the sensor wires grounded except for TPS so I was stunned that it started.

And the proof!
[youtube]http://www.youtube.com/watch?v=PyEIwaMfJD8[/youtube]

[hybrid]

Well progress has been slow, but I did a little bit today before my rivet nut tool broke

I've spent a fair bit of cash on fuel lines and connectors. I just need one more to finish it off.
I had to make a new fuel rail to fit the new smaller injectors.
I also attached some heat shield to the top of the sub frame to try and keep my arse from frying.

[hybrid]

My girlfriend is in Japan for a couple of weeks, so as well as installing ducted air conditioning into our house, I've also got some time to work on the bike.

I've put the throttle bodies back together and hooked up the coolant lines, so I can now run the bike for longer.

My tune is still way too rich outside of idle, and I'm having trouble with my LC-1 wideband controller.
I have a techedge controller as well, but I only have a guage on that.

I'm hoping to get a base tune from MK who is also using alpha-n tuning on his RZ350.

Heres a video from tonight. Its a bit dark, so I might make another one tomorrow during the day.

[youtube]http://www.youtube.com/watch?v=H_kdntwfaSo[/youtube]

[hybrid]

Hi all,
I got the bike back from the painters today.
Not completely happy with it, but it looks okay. He did not modify the seat like I asked him to and decided to have a hissy fit and basically tell me I didn't tell him I wanted that done

The stripes also do not follow the same lines.


Needless to say I will not be recommending him to anyone.


Hi Res: https://www.winsto.net/piggie/rz500proje ... paint1.jpg

Hi Res: https://www.winsto.net/piggie/rz500proje ... paint2.jpg

Hi Res: https://www.winsto.net/piggie/rz500proje ... paint3.jpg

[hybrid]

Thanks guys.

Steve, I actually painted my RD myself in 2part enamel and was pretty happy with the result. The only reason I didn't do this job myself (or get an automotive painter to do it) was because of the mods I needed done to the seat unit - which consequently weren't done by this guy anyway!

He basically called me a liar and said I didn't ask for it to be done.
Bottom line is I should have given him instructions in writing.
In the end, the seat is usable, its just going to have larger gaps near the tank and frame than I would have liked.

Gene,
the fairings and seat unit are YZR500 units from Mick Costin.
The tank is VFR400 NC30.

Thanks for your kind words fellas.
It does look good... its just these small things will definitely get on my nerves because I know they are there.

[hybrid]

Long time since I have been here other than when the server has issues!

So today I had some spare time and decided to get started on swapping over to PWK28 carbs from the 40mm injection, since the ECU is now controlling this in my Mustang:

It's been around 3 years since I have used this bike, other than to ride it to be registered, and last year I didn't even register it, so I will need to get it inspected again.
The bodywork has been off it for a long time (keeping it inside).

My nicely painted engine is not so nicely painted any more!

I bought two sets of Banshee cables to do the job.

Couple of hours later:


Luckily I kept the original manifolds, so maybe tomorrow I'll finish it off.

[hybrid]

Started my hydraulic clutch conversion.
Tried modifying the original cover, but with the magnesium in it, it would not weld very well.

So started from scratch with some 6mm ally.
The slave is a brand new Suzuki VS750 item that I picked up cheap.
I picked up a radial master also. I hope they work together
Need to buy the hydraulic line now.




It's not finished yet. I still need to get some tube to weld on the back as spacers to the engine cases. I also need to make up a bush to support the gear lever shaft and weld it in place.
After that I can tidy up the edges and give it a lick of paint.

[hybrid]

Got the bronze bushing and ally tube, so I have finished off the plate for the slave cylinder.

Now I'm just waiting on the hydraulic line and I should be good to try and get this thing back on the road again.

[hybrid]

Job done... now I just need to sort out my fuel lines and get some filters made and we're back in business.
Might even be able to take it for a ride on the weekend without filters if I'm lucky.

The clutch is so much lighter now. The difference is chalk and cheese. Well recommend the mod to anyone with a custom bike that has heavy springs.

[hybrid]

Got it running today.
Need to tweak the clutch a bit. It's hard to get in to neutral at the moment, but damn it's smooth.

I've got the PWK28's running 137.5 mains at the moment.
F*ck me, this thing is much faster than before. It wants to lift the front wheel every time in first when it comes on the power. Considering how highly geared this thing is at the moment, it's pretty scary!

Before I put all the fairings back on, I'm going to spend some time cleaning up the front wiring though.

[hybrid]

Right... guess what I'm doing this weekend.



Got some random fouling issues, so decided to start with a clean slate instead of fiddling with second hand carbs.

I have a feeling it might be the chokes. I'm using the RZ500 plungers in the PWK carbs I think. So if it still fouls with these new carbs, choke is the first place I'm going to look.

Going to start with them out of the box and see how it goes.