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OK....This is the OFFICAL start of my turbo build.
Some of you are gonna ask why, for what, what a waste...blah blah blah. I've did the 1127 swap already (1216 actually), ive did subframe and two tail swaps, rim swaps, streetfighter....sooooo.....my little mind has been pondering this idea for a while now and since i got done building my GS Kart a few weeks ago, what a perfect time it would be to start boosting the kat.
Little history on this bike. Bought it in may or june of '09 (kat #15) Was in rough shape, got it for $200 (with a title) and it ran. Replaced the front fairings, windscreen, levers, oil pan, a side cover and master cyl. Then i tossed on a set of post98 rims, Rear lowering kit, and then painted it. jetted the carbs and got a v&h exhaust....i have maybe $600 in the bike including the cost of the bike, the paint and supplies cost the most.
The bike (The orange one)
Majority of the parts needed
I was originally gonna use a KKK KP31 turbo from a smartcar fortwo, but after getting it in the mail and seeing that it was the smallest turbo i have ever seen (even smaller than the garret gt12) i knew i couldnt use it. So i then went and bought a brand new turbo, a little on the big side but will suit my boost range goal of 5500 rpm-11,500 (stock redline is 12,500 on a 750, and well get into that later) and at a moderate 7-8 psi. (the motor is capable of handling 10psi on stock compression, but id rather be safe)
KP31 vs t3/t4 .50 trim
So today i mounted the fuel pump, which is from NOS. Its the high flow one that puts out a max of 14psi. Ill be at around 10-11 psi on full boost.
so no worries of burning the pump out (too fast). Mounted the RRFPR (fuel reg.) Plumbed most of the boost lines. Mounted the boost controller and found a pretty trick place for the boost gauge.
The sending unit was shot anyways...
Ok Ignition you might ask, "Arent you gonna detnate you motor if your dont retard your timing" at 8psi, probably not, but i am installing a dyna2000 with 3.0 ohm coils (green). The retard will be activated via boost switch or micro switch. I have the switch set at 3psi.
Intake plenum: I havent built it yet but i made my card board template. And i must say, it fit pretty damn good for not even having the airbox out of the bike before i started guesstimating dismensions. I was gonna do a log style plenum at first, but i wanted to have twice the volume as the motor does in displacement for lag reasons.
The plenum (template) actually sits flush on the frame above the rear shock, so i have a solid place to mount it. im running a pitot on the inlet of the plenum to pressurize the carb bowls. Now my blow off valve is gonna be on the plenum or the charge pipe depending on how i route it. Im gonna cringe when i have to cut and shave my freshly painted plastics. im hoping to route the pipe over the battery and down into the front portion of the side panel and hopefully most of the cutting will be on a least expensive rear fairing (i dont have any spares...lol)
Parts im waiting for still:
-external wastegate w/ 4psi spring
-wastegate flanges
-5 bolt downpipe flange
-scavenger pump for the oil return
Im going to mexico tomorrow (tues) with the wife for a week, so i doubt ill be playing with it today. So be patient with me if you follow this thread. After i build the plenum and header it should be smooth sailing
Thanks for looking
Rob
Some of you are gonna ask why, for what, what a waste...blah blah blah. I've did the 1127 swap already (1216 actually), ive did subframe and two tail swaps, rim swaps, streetfighter....sooooo.....my little mind has been pondering this idea for a while now and since i got done building my GS Kart a few weeks ago, what a perfect time it would be to start boosting the kat.
Little history on this bike. Bought it in may or june of '09 (kat #15) Was in rough shape, got it for $200 (with a title) and it ran. Replaced the front fairings, windscreen, levers, oil pan, a side cover and master cyl. Then i tossed on a set of post98 rims, Rear lowering kit, and then painted it. jetted the carbs and got a v&h exhaust....i have maybe $600 in the bike including the cost of the bike, the paint and supplies cost the most.
The bike (The orange one)
Majority of the parts needed
I was originally gonna use a KKK KP31 turbo from a smartcar fortwo, but after getting it in the mail and seeing that it was the smallest turbo i have ever seen (even smaller than the garret gt12) i knew i couldnt use it. So i then went and bought a brand new turbo, a little on the big side but will suit my boost range goal of 5500 rpm-11,500 (stock redline is 12,500 on a 750, and well get into that later) and at a moderate 7-8 psi. (the motor is capable of handling 10psi on stock compression, but id rather be safe)
KP31 vs t3/t4 .50 trim
So today i mounted the fuel pump, which is from NOS. Its the high flow one that puts out a max of 14psi. Ill be at around 10-11 psi on full boost.
so no worries of burning the pump out (too fast). Mounted the RRFPR (fuel reg.) Plumbed most of the boost lines. Mounted the boost controller and found a pretty trick place for the boost gauge.
The sending unit was shot anyways...
Ok Ignition you might ask, "Arent you gonna detnate you motor if your dont retard your timing" at 8psi, probably not, but i am installing a dyna2000 with 3.0 ohm coils (green). The retard will be activated via boost switch or micro switch. I have the switch set at 3psi.
Intake plenum: I havent built it yet but i made my card board template. And i must say, it fit pretty damn good for not even having the airbox out of the bike before i started guesstimating dismensions. I was gonna do a log style plenum at first, but i wanted to have twice the volume as the motor does in displacement for lag reasons.
The plenum (template) actually sits flush on the frame above the rear shock, so i have a solid place to mount it. im running a pitot on the inlet of the plenum to pressurize the carb bowls. Now my blow off valve is gonna be on the plenum or the charge pipe depending on how i route it. Im gonna cringe when i have to cut and shave my freshly painted plastics. im hoping to route the pipe over the battery and down into the front portion of the side panel and hopefully most of the cutting will be on a least expensive rear fairing (i dont have any spares...lol)
Parts im waiting for still:
-external wastegate w/ 4psi spring
-wastegate flanges
-5 bolt downpipe flange
-scavenger pump for the oil return
Im going to mexico tomorrow (tues) with the wife for a week, so i doubt ill be playing with it today. So be patient with me if you follow this thread. After i build the plenum and header it should be smooth sailing
Thanks for looking
Rob
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