El Gringo

Aye, it's an all or nothing thing with attaching stuff, trouble is i'm trying not to change to many things at once to narrow down the issues

I have but only when it's running through the regulator, at the moment i'm just running off a remote bottle to get it running right initially. Getting the proper tank on and off is a right pain in the arse as theres not much space under it for the hoses and there's not enough space for a shut off tap under the tank. The tap is down behind the plenum before the pump and won't fit past it so when i disconnect the main flow hose from the tank it's a case of trying to turn the fuel away from the outlet so i don't soak myself in fuel (again......) It's really not ideal and i need to find a better solution. The return hose is fine and should be a big enough bore all the way along the system

Unfortunately not much i'm afraid boss. Clipped another half a coil from the regulator spring to try and drop it down a bit more - haven't had chance to try it again yet. Have re cleaned the carbs and reset the float heights to 23mm to try and cure the flooding but haven't had chance to fire it up. The other spring turned up and as Rob said it's completely the wrong size, nevermind eh? Hopefully i'll get a few evenings on it this week - need to weld up a bracket for the rear light, then i think that's pretty much all the fabrication stuff done. I've bought a proper remote fuel tank so i can run it up for longer without forgetting to stick fuel down the funnel! I'm going to try and get it revving a bit cleaner before i try the tank again. One small step at a time

Cheers Boss, long way to go yet though. Once i've got a base setup on the carbs and it'll rev cleanly it'll be off to the dyno to see what it's actually doing. It's a continuing lesson in being methodical and logical with making adjustments - one step forward and hopefully no steps back now

I bought the 1-3psi one - i did wonder whether it would be right as the FPR009 wasn't on the list, Ah well was only a couple of quid, i'll just have to clip a bit more off the existing one

Ta Rob. It started sweet as a nut without the pump, as soon as i flicked it on it stalled. Will lower the heights and drop the new spring in when it arrives

Right, bit of an update and a question I've got it so it'll start pretty consistently now which is good but the revving is still stuttery. I've plumbed all of the turbo gubbins on, so it's now with the plenum on, up pipe and pitot connected. Fired it up last night with the tank on for the first time - started ok as normal but as soon as i flicked the fuel pump on it seemed to drown it and it wouldn't re start. Plugs were soaking when i whipped them out. Now, at present the fuel pressure gauge is showing a smidge under 2.5psi, after i clipped a coil off the regulator spring. Float heights are set to the standard height of 20mm. Would I be right in thinking I probably need to go back and lower the float heights to say the 22mm i had it on before. I put them back to stock when i thought that's what was casuing it to not start. Also would it be worth clipping the regulator spring a bit more and trying to get the base pressure to around 1-1.5psi? In the first instance i'm going to go back over the carbs and see if i can get it revving cleanly running it on the bottle but with all the turbo gubbins attached. One thing at a time

Bit more progress of a fashion. It was very reluctant to start again after leaving it a couple of days, eventually it fired up so i let it get really warm, fan kicked in and out as it should, and the warmer it was the better the reluctant starting got. Couple of issues have surfaced - it doesn't really want to rev cleanly, it will but immediately dies if you shot the throttle. Secondly there appears to be a lot of oil in the air outlet from the turbo which is a worry. The dump pipe and headers have blued up very quickly too, i guess it's running hot from standing still. I haven't actually check to see if the turbo is spinning yet - it's got a 1mm restrictor in the oil line but there doesn't seem to be a lot of oil for the scavenge pump to be dealing with when it's running. Turbo doesn't smoke which is good Any ideas?

It's been a trial indeed, best part of 6 months messing around. Worst part is the false positive it gave when it fired up the first time - i have no idea how it started!

It's amazing what can happen when you've got a matched trigger wheel and CDI unit............. Didn't run it too ling as there's no coolant in it and it's late (and i like my neighbours - f**k me it's loud) but it's proof of concept To say i'm happy is an understatement! Apparently they swapped CDI and trigger wheel in '93 - guess which muppet didn't know that when he bought a '91 CDI...........

Nice one boss, i did see those springs on there. I emailed the malpassi people about them to see if they fitted the 009 regulator and they were less than helpful about whether it would or not. Will be interesting to see if it works

Right, a further update, wiring loom is now finished-ish, idiot lights now all work and i've re-done the connector into a single multiplug It's as neat as it's going to get, there's not a lot of space under the tank for the main bulk of the loom so it is what it is. Got all the turbo bits back on, all bar the last bend between the plenum and up pipe so it's still N/A for starting purposes Also got round to cleaning the inside of the tank using phosphoric acid Top job! Before After Also came to the conclusion that the battery i've been using is tatered, so i have a new one on charge ready for trying again this evening, i shall be praying to the gods of internal combustion for a miracle!

Quick update, i haven't set fire to it (yet) but i've had some more faffing with the loom so i've stripped it all back off again and have re-done a lot of the connections. Upside is it looks a lot neater and hopefully that'll be it done with - should be able to get back to trying to get it to run again! I've clipped the FPR spring so should be able to get the pressure down sufficiently to stop it over coming the float bowls - when i tried running it again, i raised the floats back to standard height and it started a lot easier so i think that may have been a good part of the issue in the first place - will leave them as they are and see how i get on. I shall not be defeated

Spot on! I look forward to seeing it in the flesh tomorrow!

She's a runner (of a fashion again)

Cracked it! Tried the new solenoid, no change, seemed to be an issue in the switch gear at the button. Stripped, cleaned and resoldered the starter button, no change. Stripped the middle section of the loom back where we shortened it, double checked feeds etc, no change. Tracked it back to the side stand relay, if i looped out the main side of the relay it turned over fine. Checked the relay, was working correctly but not staying open when the button was pressed. Started un-wrapping the loom, found a partial break in the earth wire that would have gone from the sidestand relay to the sidestand switch, sorted that out, and we're back to turning over on the button again! Yay! That was a lot of faff to get back to square one again but relieved to have found it. I think it must have pulled when we had the loom off to wrap it. So.....back to trying to start the flippin thing now. One thing i noticed when trying it earlier, when it was turning over, I only seem to get one very poor spark from each plug each time I pressed the starter button - whether this is related to the poor earth to the sidestand switch i don;t know but i'm hoping it is!

Thanks @Madb, yep the trigger side, new solenoid arrived yesterday so will check it later It's driving me up the wall! Hopefully once this is sorted i can go back to trying to get it started

We're a long way from that unfortunately Madb, hopefully i can clear up these wiring/starting issues soon and start on the turbo bit! Did a few more tests last night. With the +12v to the solenoid disconnected and a +12V applied direct from the battery to the terminal on the solenoid it turns over sweet as. So i checked the +12V feed to the solenoid from the starter button - here's where it gets odd. Disconnected from the solenoid i get +12V when pushing the button at the plug - with it connected to the solenoid and testing it on the terminal the voltage jumps all over the shop?! Very odd. I've ordered a new solenoid to double check. Also checked the voltage back at the point we spliced the loom and you get the same result - perfect +12v with the wire disconnected from the solenoid, jumpy voltage with it connected

I suspect it's the wiring @Tombola Will do a few tests later and see where it's breaking down

I think it's either the solenoid control side or the starter wiring Had a burst of inspiration, bridged across the soleniod with a screwdriver, turns over fine, so i may have ballsed up where i shortened the wiring or the solenoid low side is fubar. Either way it's progress! (And a lesson in only changing one thing at a time when you have a problem!)

Little bit more of an update After struggling to get it started after filling it with coolant and subsequently finding cylinders 2 and 3 had coolant in them, i replaced the head gasket and gave he bores a quick hone as they were incredibly shiny. I put the set of machined pistons i have in, and tried again. It coughed and spluttered but refused to start. After much faffing and starting attempts the starter motor gave up and disintegrated. I fitted a new one at the weekend - still no joy, won't even turn over now, even with the plugs out The other curious thing, my oil feed comes from the timing case on the left of the engine from the end of the main oil gallery. Normally this just dead heads against the inside of the cover, mine has a take off welded on with a threaded insert for the oil line restrictor. With the timing cover off the bike, you can press the starter button and the bike will turn over, oil pumping out of the feed. If i put my thumb over the oil feed it stops it turning over?! It's like it hasn't got the ommmph to overcome the oil resistance - it was fine before and i haven't changed a single thing on the oil side. I'm thinking there's something gone tits up in the loom, or its a weak starter. The only thing i've done is replace the starter with a known good one (i have another coming today to rule that out) and we shortened the middle of the wiring loom last weekend, one wire at a time, so maybe something has gone amiss with that Somewhat confused/bemused now

Thanks @Tombola, gives me a good idea where to start, Cheers I'm having a nightmare with mine at the moment, hopefully be at a point to clip the spring soon

You might be waiting a while. I can't even get my bike running normally aspirated, let alone with the turbo! I'll see about clipping the spring soon though, i'm aiming for 1-2 psi base pressure because the carbs on the 400 are so delicate

I haven't done mine yet, but i'm sure it's probably worth going half a coil at a time

They're supposed to be 5psi out of the box. Mine adjusted down to just under 3psi with the adjuster wound right off, needs the spring clipped a bit to get down to 1-2psi