xs650 Sumotrack

Ah, makes sense. Are you going to do aluminium or stainless? Sometimes it's pretty amazing you can do stuff when you really want to. I havent been in that much hurry last several years ;D
 
Probably stainless, the pivot pin is 15-5, the hex piece is 17-4, and the bushing is aluminum bronze, mostly out of the scrap bin from work. So I'll probably do some cardboard aided design to figure out the lever shape.

Funny part is this winter I'll be pulling the motor again to put an xs1 cam in. I want to dyno the bike once I have a decent tune in, then dyno again with the xs1 cam to see the difference.
 
I'll be happy to know as well, I've had an XS1 cam sitting around a few years now.
 
Well some progress has been made, the replacement shift fork and 4th sliding gear and now it stays in first when you want it to. The new starter gear #4 and I no longer get the nasty grinding sound with no cranking.

I put about 15 miles on it testing things out close to the house, still has a bit to go on the tune. Off idle is a bit wonky, that'll take some tweaking to get right. But it is getting closer to being able to go out further. The PMA provides plenty of charge, cruises at 14v even with all the load on it.
 
Great bike. I came across these on ebay, just a suggestion, I think they are 32mm www.ebay.com/itm/2013-2017-KAWASAKI-NINJA-300-EX300-OEM-MAIN-FUEL-INJECTORS-THROTTLE-BODIES/283018841675?_trkparms=aid%3D444000%26algo%3DSOI.DEFAULT%26ao%3D1%26asc%3D52910%26meid%3Dddd962efb7124a8b80f3b18e5fc7459b%26pid%3D100752%26rk%3D3%26rkt%3D6%26sd%3D253687248166%26itm%3D283018841675&_trksid=p2047675.c100752.m1982. any how good luck with the tunning
 
Popeye SXM said:
Great bike. I came across these on ebay, just a suggestion, I think they are 32mm www.ebay.com/itm/2013-2017-KAWASAKI-NINJA-300-EX300-OEM-MAIN-FUEL-INJECTORS-THROTTLE-BODIES/283018841675?_trkparms=aid%3D444000%26algo%3DSOI.DEFAULT%26ao%3D1%26asc%3D52910%26meid%3Dddd962efb7124a8b80f3b18e5fc7459b%26pid%3D100752%26rk%3D3%26rkt%3D6%26sd%3D253687248166%26itm%3D283018841675&_trksid=p2047675.c100752.m1982. any how good luck with the tunning

Only problem is that you can't respace them. If I was going to smaller ones I'd probably pony up the cash for a set of gpz1100 throttle bodies since they are each seperate. If the spacing matches it would be nice and easy though. I think that's part of the reason the early 2k gsxr600 ones are popular, easy to respace.

Thanks Justin!
 
Fuel sending unit version 2 is done. This will allow better flow, with less points to possibly leak pressure. Fuel pressure regulator is from a kawasaki ninja 650, the cap of the small chamber was machined for it to fit and be held in with a snap ring. The cap has an o-ring seal with the body. The nipple on the side is for the fuel pump to connect, and the wires will be terminated with ring terminals and bolts passing through the delring piece that has 3 orings for a seal with the body.
 

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Well the new fuel set up was installed in the tank. Holds fuel pressure better and higher than the old set up. Took it for a test ride and once I hit 4400rpm above 42% throttle a cylinder was dropping out on me. Must have been a sticky injector because I swapped it for a spare and suddenly it is way too rich everywhere.
 
Ok, clean injectors in and a very leaned out fuel map finally has it running to redline without dropping a cylinder. Pulls well all the way to the rev limiter that is set at 7500rpm, I could probably raise that to 8000k since the factory redline is 7500. But I can finally go on a longer ride and really let autotune do its thing. It has been an adventure working on the efi with no baseline map to start with. The good thing is that once I get a nice long datalog I can look at switching to ITB mode.
 
Ok, so it is on the road now. Handles well, is nice and stable, tracks straight if I let go of the handlebars. Tuning is coming along, it pulls all the way to redline now, and pulls from just above idle in 5th gear. It does have a slight hiccup when pulling from low rpm, but more riding with autotune will help get rid of it. Working on smoothing out the cold start a bit more, and last things left are to mount the horn, and paint the numberplate.
 

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Beautiful bike. Well done.

What autotune/I controller are you using? I have a Bazzaz with autotune. Even though the Bazzaz uses an average for the cells (rpm/throttle position) that it hits, the tuning, in my experience, seems quite dependent on riding conditions. I look forward to your experience.

R
 
I'm using a microsquirt ecu, with tunerstudio on my laptop. I use the autotune feature of tunerstudio to get it real close, then once cells don't change more than 2-3% in a ride I'll stop autotune and switch it to having the wideband in control. I can set it to give the wideband 5% and it'll correct itself within 5% of the set map. I've used this process before tuning a triumph spitfire with a 4age and ITBs before and after the first 300 or so miles of letting autotune do its thing, I switched the ego control on and haven't had to change anything in 3 years and about 10k miles.
 
Well I got the rear brake sorted today, and got the 10 micron fuel filter connected. The fuel filter does need a mount made for it, I have the material I just need the time. But my buddy stopped by and got a short video coming down the street for me.
https://youtu.be/cetNZ7BQ3g0
 

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Thanks! I was worried about it being too loud.

Yeah, it steers well. Stable up to 70mph, thats just the fastest I've gone so far, tracks straight when I let go of the bars, leans into corners well without feeling twitchy or heavy. Overall it feels very neutral handling. Setting it up I adjusted everything so it has 24.7* of rake just sitting, offset is 30mm and I'm going to leave it. I had thought about increasing the offset, but it feels good. Possibly in the future I'll look into a slightly lighter springrate up front as it is a little harsher than I would like, but I'll try the damping adjustment first.
 
What 's the weight compared to ther bike forks are off? If it's within 50~80 lbs you should be able to tune it out with lighter fork oil and compression/rebound damping adjustments. Springs should also be relatively cheap if you need them as 'straight wound' are always used in modern 'cartridge' forks (the progressive damping rates don't work with progressive (multi-rate) springs
 
The zx6 the forks came off of had a 421 curb weight, a stock xs650 is supposed to be about 480. I'm sure mine is lighter than stock, but I don't own a scale. I already backed the preload down, and I'm about to see if adjusting the damping makes a difference. If that makes a difference but I feel it needs more I'll try lighter fork oil, and then last step will be new aprings.
 
Damn bud, very inspiring, BOTM once you get it totally sorted. Honestly, this is one of the best builds on here.
 
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