My KZ440 / KZ400 Cafe Project(s) – Turbocharged 440, Daily 400
- Thread starter mcge8241
- Start date
Got back on the 400 this week....it's been beautiful and crazy warm in Michigan!
Ordered some rearsets for this bike and some different grips...hopefully some soft grips and an improved riding position will make it more comfortable. It's not that it's uncomfortable but the aluminum grips hurt my hands after a hundred miles or so.
I'm having the tank re-painted...I used that Kreem sealant on the inside of it over the winter and it was just fine for 3 days...but then I rotated the tank and just let is sit at a different angle...must have distrurbed some gas inside or something because this was the result:
Sanded it all down and will be picking it up tomorrow hopefully.
Anyways I spraybombed my other tank with hammer paint...just some silver to get me on the road. 200 miles so far and no problems!
I'll take some pics once the rearsets come in and the new tank is on...it should change the look of the bike a bit too because I'm losing more frame in the process.
As for the turbo bike I really havent touched it all winter. But now I'm very motivated again....I have been collecting parts however. I'll probably take some pics tonight and do another update. The long and short of it is that I got a set of throttle bodies with EFI off eBay and I plan to hack them up and make them work for my project. I've also got the efi controller I plan to use on it in my hands too...and the fuel pump.
I still need to hammer out how I will set up the sensors...I need to have at least:
- Engine temp
- Throttle position
- Air intake temp
- crank position
- cam position
The only tough one is going to be the cam position...I will have to add a toothed wheel to the camshaft or have some sort of magnetic pickup off the head somewhere....I need to pull the engine out and take the valve cover and look around really well...you can only tell so much from pics on the internet
Till later, enjoy the weather folks'
Ordered some rearsets for this bike and some different grips...hopefully some soft grips and an improved riding position will make it more comfortable. It's not that it's uncomfortable but the aluminum grips hurt my hands after a hundred miles or so.
I'm having the tank re-painted...I used that Kreem sealant on the inside of it over the winter and it was just fine for 3 days...but then I rotated the tank and just let is sit at a different angle...must have distrurbed some gas inside or something because this was the result:
Sanded it all down and will be picking it up tomorrow hopefully.
Anyways I spraybombed my other tank with hammer paint...just some silver to get me on the road. 200 miles so far and no problems!
I'll take some pics once the rearsets come in and the new tank is on...it should change the look of the bike a bit too because I'm losing more frame in the process.
As for the turbo bike I really havent touched it all winter. But now I'm very motivated again....I have been collecting parts however. I'll probably take some pics tonight and do another update. The long and short of it is that I got a set of throttle bodies with EFI off eBay and I plan to hack them up and make them work for my project. I've also got the efi controller I plan to use on it in my hands too...and the fuel pump.
I still need to hammer out how I will set up the sensors...I need to have at least:
- Engine temp
- Throttle position
- Air intake temp
- crank position
- cam position
The only tough one is going to be the cam position...I will have to add a toothed wheel to the camshaft or have some sort of magnetic pickup off the head somewhere....I need to pull the engine out and take the valve cover and look around really well...you can only tell so much from pics on the internet
Till later, enjoy the weather folks'
turbodog
Active Member
Hey, just ran across this. I'm doing a turbo/Megasquirt EFI xv920 Yammie. Sacriligious? Maybe, in terms of historic cafe racer BIKE formula. But, not, IMO, in terms of the cafe racer PERSON. Mixing and matching parts, making boneyard parts fit where they have no right to fit, gaining performance one part swap at a time...
If there had been factory turbo bikes around in the late 50's, early 60's, and parts started showing up at the boneyards... how long do you think it would have been before a guy showed up at the local cafe with a turbo on some completely different make/model bike? Not long, I'd wager.
Now, if you are really into the costume-party / re-enactment thing (and there's nothing wrong with that!), a Japanese bike with a turbo probably doesn't fit. After all, one does not show up at a civil war re-enactment sporting a M16.
But, if you are truly carrying forward the creedo of the cafe racer PERSON.. i.e. make it faster, with your own 2 hands, using parts you scrounged (used), then DIY EFI and turbocharging make perfect sense.
If there had been factory turbo bikes around in the late 50's, early 60's, and parts started showing up at the boneyards... how long do you think it would have been before a guy showed up at the local cafe with a turbo on some completely different make/model bike? Not long, I'd wager.
Now, if you are really into the costume-party / re-enactment thing (and there's nothing wrong with that!), a Japanese bike with a turbo probably doesn't fit. After all, one does not show up at a civil war re-enactment sporting a M16.
But, if you are truly carrying forward the creedo of the cafe racer PERSON.. i.e. make it faster, with your own 2 hands, using parts you scrounged (used), then DIY EFI and turbocharging make perfect sense.
Maybe not in the 60's but KZ100 had EFI, Honda, Yamaha and Suzuki all had Turbo models in production at one time. That's all good. I have a 76GT750 Suzuki that I want to EFI after I finish drilling and grinding extra ports to go with the reed valve conversion. For that I think MS3x will be the way to go. I need sequential injection on three channels by two injectors each, so a microsquirt won't cut it.
A MoTeC M48 might work too but it's ten times more expensive -smaller footprint and neater, but that's a heck of a premium.
A MoTeC M48 might work too but it's ten times more expensive -smaller footprint and neater, but that's a heck of a premium.
Sorry for the lack of update folks, I'll try to get some pics tonight.
I have a microsquirt board that will be controlling the EFI stuff. I'm using throttle bodies from what I think was an R6. I have 2x sets, in varying conditions. I believe they are Mikuni throttle bodies. Anyways, they should be pretty easy to split and the spacing is "close" to that of the KZ440...and it should be easy enough to fab up holders/boots/some sort of manifold.
What really confused me about the throttle bodies is that I was under the impression that this particular R6 had electonic throttle control...which it did. I couldnt tell much from the pics on eBay, but it looked as though there was a stepper motor for the throttle control AND there was a cable linkage. Further, the throttle its self has two cables...as evidenced from other eBay listings. I got each set of TBs for about $30 shipped.
Anyways once the first set got here I started taking them apart. They were very corroded (which I why I got a second set), but it was pretty clear how the bike operated...it was indeed cable driven throttle, but the way the linkage is designed the cables do nothing more than force the throttle to close...they can NOT open the throttle, there is a break in the linkage that makes them only work one way. Confusing, but when you try to use the throttle to open the TBs, the linkage turns one TPS sensor but wont physically open the throttle...that is done by the stepper motor which mounted between the two banks of TBs, only the motor physically opens them. I guess there is a computer on the bike that reads the input from the throttle linkage TPS, uses that to drive the stepper motor and open the throttle, and it verifies the angle with a second TPS sensor on the other end of the shaft. Complex but I'll take some pics later and demonstrate it.
I guess the point was that you want a PHYSICAL return for the TBs, as in the event of an electrical or computer failure you could at least avoid a jammed open throttle because of electronics.
Anyways, I plan to split the 4 into a good set of 2 with the linkage on the one side and one TPS sensor. Then I'll just connect the break in the cable throttle linkage, and walah I have throttle-driven TBs for efi, complete with injectors, rail, and a TPS sensor.
I have a microsquirt board that will be controlling the EFI stuff. I'm using throttle bodies from what I think was an R6. I have 2x sets, in varying conditions. I believe they are Mikuni throttle bodies. Anyways, they should be pretty easy to split and the spacing is "close" to that of the KZ440...and it should be easy enough to fab up holders/boots/some sort of manifold.
What really confused me about the throttle bodies is that I was under the impression that this particular R6 had electonic throttle control...which it did. I couldnt tell much from the pics on eBay, but it looked as though there was a stepper motor for the throttle control AND there was a cable linkage. Further, the throttle its self has two cables...as evidenced from other eBay listings. I got each set of TBs for about $30 shipped.
Anyways once the first set got here I started taking them apart. They were very corroded (which I why I got a second set), but it was pretty clear how the bike operated...it was indeed cable driven throttle, but the way the linkage is designed the cables do nothing more than force the throttle to close...they can NOT open the throttle, there is a break in the linkage that makes them only work one way. Confusing, but when you try to use the throttle to open the TBs, the linkage turns one TPS sensor but wont physically open the throttle...that is done by the stepper motor which mounted between the two banks of TBs, only the motor physically opens them. I guess there is a computer on the bike that reads the input from the throttle linkage TPS, uses that to drive the stepper motor and open the throttle, and it verifies the angle with a second TPS sensor on the other end of the shaft. Complex but I'll take some pics later and demonstrate it.
I guess the point was that you want a PHYSICAL return for the TBs, as in the event of an electrical or computer failure you could at least avoid a jammed open throttle because of electronics.
Anyways, I plan to split the 4 into a good set of 2 with the linkage on the one side and one TPS sensor. Then I'll just connect the break in the cable throttle linkage, and walah I have throttle-driven TBs for efi, complete with injectors, rail, and a TPS sensor.
Temp dropped so I sort of lost my momentum, but I did get some stuff upgraded on the 74':
-Rearsets from an 07' GSXR 1000, got the pair on eBay for $80 shipped! Bought stuff to make the linkages from McMaster Carr...have about $150 into the entire setup. I still need to re-locate the kick stand but I love the short throw on the shifter and the new riding position
-Modern headlight with an H4 bulb. Again got it on eBay for like $30 shipped. I bought just the housing and made it fit in the standard KZ400 bucket. MUCH improved range and width at night, and has a high-low ability too.
-Tank fixed. new paint, new vinyl, looks great!
-New grips. Not as sexy but much more comfortable
-Clock. Now I have no excuse for being out too late...the wife was complaining.
-Vintage keychain. Just for the LOLZ
Pics say more than words:
-Rearsets from an 07' GSXR 1000, got the pair on eBay for $80 shipped! Bought stuff to make the linkages from McMaster Carr...have about $150 into the entire setup. I still need to re-locate the kick stand but I love the short throw on the shifter and the new riding position
-Modern headlight with an H4 bulb. Again got it on eBay for like $30 shipped. I bought just the housing and made it fit in the standard KZ400 bucket. MUCH improved range and width at night, and has a high-low ability too.
-Tank fixed. new paint, new vinyl, looks great!
-New grips. Not as sexy but much more comfortable
-Clock. Now I have no excuse for being out too late...the wife was complaining.
-Vintage keychain. Just for the LOLZ
Pics say more than words:
Bobbed_out
Been Around the Block
Nice...
Got another bike today. This one might end up getting the turbo, I haven't decided yet. It's a 78' KZ750 twin. 8k on the clock, and fucking clean as hell.
Tons of stock parts, and aftermarket stuff too, came with it. I'm picking it up in a week and I'll snap some more pics then.
Tons of stock parts, and aftermarket stuff too, came with it. I'm picking it up in a week and I'll snap some more pics then.
two-smoker
I reject your reality, and substitute my own!
Damn, I was looking for one of those when I found my TX.... Looks like a good base for a project!
Shermanator86
Big guy on a little bike
So any update on the turbo build? Looks like a nice 750 you picked up as well.
