Breadman

Fuel filter info noted. Cheers. Front brakes have come to life overnight. And managed to weld some fuel line fittings onto the tank.

Fuel Injector testing this week and with the unmodified fuel rail, there was a significant lack of fuel on the right hand cylinder. After modification of the fuel rail, I now have a very steady flow across all injectors. I even moved the injectors across to different cylinders and everything still seems ok. In other news, the front brakes are proving to be a pain to bleed so it's a cable tie around the lever and I will return to that next week. I have to remove the swinging arm again as I'm not happy with the clearance between the frame and chain. I have a better condition chain guide rubber so it is a good time to fit that. The bandit swinging arm in the Gsxr frame gives a shorter wheelbase and I have also got a smaller rear sprocket. This means the chain runs much closer to the swinging arm so a better condition chain guide is a good idea. The brembo clutch master cylinder looked good on the outside, but the piston and seals needed replacement. New parts ordered and yet another job for next week. The blue petrol tank in the previous pictures has no mounting lugs for the frame and side panels. I have another petrol tank which I will fit but I need to weld new fuel line fittings to it. Next week will be busy and the good weather is coming so there is much to do. Another set back happened today........the fuel pump I was given has now starting to make a nasty grinding sound. The fuel tank has plenty of fuel so it's not air causing cavitation. A new pump has been ordered. I am fed up of delays caused by secondhand parts. Saving money is good. Messing around fixing stuff is bad. I also checked the fuel filter but all looks good and clean. ??

I decided to drill and tap the other end of the fuel rail so fuel is in one end and straight out the other end. The original suzuki fuel fitting has been welded shut. Injector flow testing next week.

All good info. Thank you everyone. I will change the fuel rail and get rid of the Suzuki fitting and just have fuel coming in at one end and out at the other. Makes sense really. Will test the flow from all the injectors again. FPR is in the correct place but I will check, check and check everything again.

Despite the fuel rail being pressurized @ 3 bar, was the fuel taking the path of least resistance ?????? I have now swapped the fuel pipes over so the inlet is as Mr Suzuki intended. If the problem persists, I will blank off the original Suzuki inlet and just feed the fuel in and out of the main fuel rail.

Despite my efforts of trying to tune the bike, I noticed that the spark plug on Number 4 cylinder..........as you are sitting on the bike..........seemed to be a bit leaner than the other spark plugs. I swapped the plugs and coil packs around but the problem was the same. The Suzuki fuel injection system is mounted upside down from its normal GSXR600 orientation so the injectors are on top. Fuel was entering from the left hand side of the bike and then exiting out of the original fitting, between 3 and 4 cylinders. This fitting was actually the original Suzuki INLET . I have circled this in the photo.

I have not fitted the rear brake pedal or master cylinder so lets hope it does its job.

New parts ordered and everything reassembled and then I decided to fit the thumb brake that I have from another project. It looks weird mounted on the handlebars and my one picture doesn't really help but with new homemade stainless brake lines, new fluid and it works very well. There is a surprising amount of feel when you push the lever and I actually think that it will be easier for me to handle any wheelies.

To progress further with the engine tuning, I need to finish the bike enough so I can ride it down the road. BRAKES....... I need them so I stripped down the rear brake that I had and it was useless. More £££££

With the wiring now reworked and insulated beyond what is probably needed, it was time to get the bike to start and run after my various problems. Yes, it started but something else wasn't right. Massive overfuelling problems. So I called upon Arttu to inspect the datalogs. There is so much info from the ECU and I don't know what I'm looking for, it's just so confusing. I am becoming more familiar with what is going on and how to interpret it especially when you have some help. Back to the fuel problems. I checked through the wiring as Arttu had asked me to do and the map sensor seemed to be the culprit. The sensor was reading 1.6 bar all the time and was just launching fuel into the engine. I drained the oil out of the bike and there was certainly some fuel in it. As the bike hadn't really run or been under load, I'm sure no damage has been done. Took a recommendation by Clivegto and got some Westway 10/40 oil. Definitely cheaper than what I was using. A quick fire up of the engine with no map sensor problems and the datalog showed that the fuelling was still a bit rich. With the Megasquirt, you have to let the warm up enrichment phase finish before it transitions to your main fuel table at a given engine temperature. I shut down the fuelling some more and I now have a steady idle. I am very happy with this. Just to have the bike running for 10-15 minutes after spending over a year of my life getting to this point is just so good for the soul. Brake caliper refurbishment and installation is next on my to do list as well as some further attempts with the mapping.