El Gringo

Not as yet, got it striped down ready for the smaller main jets and then i decided to sit down and eat a lot of cheese and drink a lot of port over Christmas! Will be ordering up some jets in the next week or so, so hopefully back on the dyno to test the theory sometime in January

Aye, stripped it down, carbs off ready for jets when i can find some Good news is the oil i thought was coming from the turbine outlet isn't (or doesn't appear to be) - i think it's dropping down from above, probably from the knackered exhaust thread hole. The drain hose fitting from the turbo was making a bid for freedom so that'll need nipping up again. The other good news, after 5-6 albeit short and steady runs on the dyno it has used incredibly little fuel, there was probably a litre or so in the tank, i put a full 5 litre can in and have just drained back out virtually 5 litres (he says making a comedy pretence about fuel economy)

Erm......... the adulation of your adoring fans and a block of cheese Thanks for the info Wombat, that follows what the dyno guy and Rob said - i'm on the hunt for some new main jets as I type!

Hmmm interesting, the dyno guy said that sometimes when they're massively rich it shows on the graph as lean for whatever reason That would kind of follow. I's one avenue to look at

Ladies and Jellyspoons drum roll please....................................... The final figure was................................... A whopping.............................. 22.4hp Fuck knows what was going on but it got to 6.5K rpm and hit a wall, on every run, in pretty much the same place. Just signed off and wouldn't pull through it, didn't sound like it was missing but that was as much as it would do. Tried taping up the filter, tried increasing the fuel pressure - as soon as it got to about 0.4bar on the boost gauge it gave up On the plus side, minimal oil leakage from the scavenge pump and drain, none really from the turbo itself, no fuel leaks, no coolant leaks and it didn't grenade (not that it got anywhere near having chance to!) So, next step, i've got another CDI to try just incase it's that, then to go back through and check all the hoses etc Not the great result we wanted but not a disaster!

One thing i have noticed which i'm a bit concerned about, i seem to be getting a few drops of oil directly underneath the flange of the turbo exhuaust It's obviously nice and clean as it's new but i figure i shouldn't be having oil coming from the exhaust - and i'd have thought it would be burning off rather than dripping out? It's not a huge amount but a little worrying, any ideas? I'll double check the drain gasket is in the right place I wonder if it could do with a little sump on the drain? It'll be alright for now i think but something to deal with.

Ah ha, in which case i shall let you know when i'm venturing North to see the Brother Cross

I couldn't possibly reveal my sources (but yes ) The ignition cover with the oil feed point and machined pistons came from Ian Him and Jim are a top pair of blokes, they're 500's are properly special bits of kit

Ladies & Jelly spoons! Handbags away please! It'll be what it'll be - i have it on good authority that the clutch will probably go south around the 80hp mark - on the plus side the same source does a nice lockup conversion I've re booked for next Friday so it's a nice delayed gratification, and hopefully a pleasant earlier Chrimble present I'm currently awaiting the arrival of some HD clutch springs to try and help the cause After the initial results i shall have plans underway for motor Mk2 with a few interesting ideas

I have a little more faith now, it's started everytime since doing the pick up I'm also impressed with everyones optimism! I'm reckoning on 74-75 first run without turning the boost up - i'd really like to get close to the 100 but it'll depend on the AFR

Balls, Dyno bloke has had to cancel Friday. Trying to rearrange for next week. Any bets on what it makes when it finally gets there? I'll open the bidding with the remains being swept up into a bucket

Cheers Boss, useful info I'm just excited (and nervous) about what's going to occur!

Heading over to Lee Motorcycles at Ledbury, it's about an hour away but it's the closest one to us as far as I know. Gave him a ring beforehand and explained what it was, what state it was in and what i wanted to achieve, he was happy to give it a run. He's the guy Ben at Valespeed uses, so if it's good enough for the UKs fastest 600 diversion it's good enough for me!

Bit of pre dyno leak testing

Well D-Day is set! Dyno Day booked for December the 8th Will run it up before then, probably Sunday and double check for leaks Was presented with a useful piece of info yesterday, apparently FZR600 pistons will take it to 465cc......... I feel a MkII motor coming on at some point

Cheers Boss Just about finished off the lights and wiring now D D D D D D D I'm running out of excuses for not getting it finished now

I'm just faffing now, getting some of the little bits finished up. Bought a new sandwich plate adapter and re threaded it properly this time so it's nice and square, oil lines are finished and it's now full of oil No leaks so far which is excellent! Made a start on redoing the idiot lights - the LEDs were just too fragile and were just touching on the top of the upper oil line Soooo, new idiot lights acquired and are now off with a mate being recessed into the front of the top yoke to keep it neat - D Managed to keep the nice 12pin plug which is good as it was a ballache doing all that wiring!! D Will fill the now redundant holes in the switch plate. Will also redo the switch wiring so it's tucked up neat under the clock bracket D I did check the wastegate opening pressure (mainly to make sure it actually worked), it started to crack at around 5-6psi and fully open by 8-9ish, i've no idea what this tells me other than it works and is presumably about 7psi when it starts properly venting. It wasn't the most scientific method using a footpump and a beachball inflator on a length of silicone hose but i can't really think of another way to do it Also found a nice home for the ignition key out of the way and once it's all painted black it should be nicely hidden D Hopefully my next post will be a nice video of me having a little ride to see if it makes vrooom and ptssssch noises!

Thanks Guys It has indeed been a ballache but i think once it's done it will be worth it (provided i can get 100hp out of it! lol)

Haven't had much time on the bike since my little test run but i've been able to crack on with the oil cooler. I bit the bullet and ordered up some hose and some (alot) of fittings - it's actually worked out really really tidy, well happy with it. 2 x 120 degree fittings at the top pull the hoses in the right direction to run down the side of the headstock and then down into the sandwich plate take off which has been thinned down to make it as narrow as possible and with a shorter filter (as per earlier in this thread) "just" fits under the turbo - i had to skim a little bit off the back of the lower outlet flange bolt hole but it's in and is a big thing knocked off the list! Also, been and picked up a gallon of oil ready to re fill it and i finished off re doing the boostgauge feed. Wiring under the tank has been shortened so the tank actually fits now. Just need to find a home for the ignition switch now and re do the idiot light wiring and that's about it! Then on to the dyno hopefully

Haha, funnily enough that had crossed my mind

Right then A quite momentous thing has occurred, I went for a ride on the turbo. It was only a short low revs trundle up the village but it has now moved under it's own steam, nothing fell off, nothing leaked and it ran pretty damn well! Gearbox seems really really slick too which is nice I balanced the carbs which helped with the popping and coughing at idle, and i made a new manifold that fits all 4 carb tops to even out the feed to the dump valve to stop it fluttering DSC_0712 by Chris Jennings, on Flickr I need to add a tee from this line to the boost gauge to stop it flapping around *Fuck knows why it's formatted like that?! DSC_0714 by Chris Jennings, on Flickr DSC_0716 by Chris Jennings, on Flickr DSC_0717 by Chris Jennings, on Flickr DSC_0718 by Chris Jennings, on Flickr The fuel pressure is at exactly 2psi on the gauge which is higher than before but..... the dynamic fuel level in the float bowl is actually now lower than it was previously which is awesome because it means it's not over fueling at idle. So next up is to finish the oil cooler hoses and sandwich plate and probably make up a new exhaust with some form of silencing (it's ridiculous even by my standards!) and a lambda bung port so i can set the fueling up when we get to the dyno, Also need to sort out the fucking horrendous mess under the tank, so many hoses and wires, so little space! But, for now, i'm having several celebratory beers as it's been a long time getting to this point!

I think it was about 6mm ID if i remember correctly I disconnected the BOV earlier and balanced the carbs which helped a great deal with the popping and coughing at idle - the carbs were massively out of balance. I've got some more vacuum hose and tee pieces coming to link together for the BOV feed. Got a damper for the boost gauge take off which works well to settle the needle down It's all coming together nicely. Didn't get the tank back on today, might as well wait until i've sorted the BPV feed

Ta! That makes sense I've got a pitot tube in the up pipe running to the float bowl vents so that's ok. I guess its the BOV fluttering causing the popping allowing a bit of extra air in. I think i'll tee them all together to the BOV and tweak the idles back to stock. Tank going back on later this afternoon

Next stage of testing is done, Re-introduced the blow-off valve - connected to the carb top cylinder 1 Re-introduced the FPR signal line - connected to the carb rubber stub (Normally for the vacuum hose to the fuel tap) cylinder 3 Also added the Boost gauge by tee-ing into the FPR line - mainly as the hose it came with won't fit over one of the carb tops Still starts okay but the idle is now a bit poppy/coughy at times - they are all a good fit with clips so it shouldn't be an air leak Still rev's okay which is good and it even started off the small lithium battery which was nice Boost gauge flutters all over the shop at idle, it was a cheapy one so i shouldn't be too surprised. I might try disconnecting them again to see what difference it makes to the idle. I may also lean the mixtures off slightly as it seems a bit rich - i think they're only a 1/4 turn past standard but it may help with the stumbly idle Any thoughts?