bruteforce Posted May 17, 2016 Author Posted May 17, 2016 (edited) Last saturday at 17:00 finally the ordered gaskets came in. I had some minor oilleaks so time to equalise the oilpan (was warped from welding), fit the stronger clutchsprings, and neaten everything up by making a nicer oil return for the Facet pump whilst changing back to a standard igi cover. While I was on a roll I also enlarged the mains and dropped the needles one notch. As the boostmeter is working great I now decided to shorten the cable to a decent length too. As per manual I made the boostpickup between carb and head instead of on the plenum. No time yet for a longer testdrive but we'll get there, need to paint the igi cover in GSXR grey also. Edited May 17, 2016 by bruteforce 1 Quote
bruteforce Posted May 17, 2016 Author Posted May 17, 2016 (edited) 11 hours ago, bruteforce said: As the boostmeter is working great I now decided to shorten the cable to a decent length too. As per manual I made the boostpickup between carb and head instead of on the plenum. Right, that doesn't seem to work because the boostmeter is totally hapless and indicates randomly. Back 2 the plenum it is then. It runs rich on transition now, I think it will clear up when I up the boost. Laterssss. Edited May 17, 2016 by bruteforce Quote
bruteforce Posted May 25, 2016 Author Posted May 25, 2016 (edited) Put the bike on the dyno today and it ran rich as expected. By the time we got the AFR sorted and upped the boost, the headgasket blew. Bummer, especially as this is an engine-out job on this bike. Good news is that I have it on video! Edited May 25, 2016 by bruteforce 1 Quote
Screwriverracing Posted May 25, 2016 Posted May 25, 2016 Unlucky Marco, Are the bores wired? Cheers SRR Quote
bruteforce Posted May 26, 2016 Author Posted May 26, 2016 No, just Cometic head gasket for 81mm bore. Never gave me trouble all these years of abuse before so don't know what went wrong. Will get the engine out coming weekend to see. Quote
bruteforce Posted May 26, 2016 Author Posted May 26, 2016 (edited) In the meantime we've figured out that the turbocharger must be on its way to die. Proof of the pudding is that the motor delivered just over 180rwhp on 6 psi and only 200 rwhp on 15psi. It just generates heat and I think this might have had an effect in killing the headgasket. Just hope that it's only the gasket. Always thought the present KKK K04-22 to be too small for the 1195 motor anyways so I've bought a Mitsubishi TD05H-16G for it. Edited May 26, 2016 by bruteforce 2 Quote
homer Posted May 27, 2016 Posted May 27, 2016 On 17.5.2016 at 10:20 PM, bruteforce said: Right, that doesn't seem to work because the boostmeter is totally hapless and indicates randomly. Back 2 the plenum it is then. It runs rich on transition now, I think it will clear up when I up the boost. Laterssss. Have you connected all the vacuum lines from the carbs together? Usually that helps and gives steady readings. Quote
bruteforce Posted May 27, 2016 Author Posted May 27, 2016 Hello Homer, No I didn't. I recall having tried that once and it messed up the motor. Quote
homer Posted May 28, 2016 Posted May 28, 2016 19 hours ago, bruteforce said: Hello Homer, No I didn't. I recall having tried that once and it messed up the motor. Ok. That is strange, have seen several turbo bikes with vacuums connected. Can I ask what did that do? Quote
Screwriverracing Posted May 28, 2016 Posted May 28, 2016 Get the bores wired while its apart. Cheers SRR Quote
Reinhoud Posted May 29, 2016 Posted May 29, 2016 3 hours ago, bruteforce said: In the meantime we've figured out that the turbocharger must be on its way to die. Proof of the pudding is that the motor delivered just over 180rwhp on 6 psi and only 200 rwhp on 15psi. It just generates heat and I think this might have had an effect in killing the headgasket. Just hope that it's only the gasket. Always thought the present KKK K04-22 to be too small for the 1195 motor anyways so I've bought a Mitsubishi TD05H-16G for it. I had that turbo charger on mine, it spooled up at 5000rpm, and at 5500 rpm it went flat out.. Next turbo I put on is going to be smaller. This one is from an Lancer EVO III? Quote
bruteforce Posted May 29, 2016 Author Posted May 29, 2016 Smaller!? Full power at 5500rpm is OK with me. This one's off a Subaru Impreza WRX Quote
bruteforce Posted May 31, 2016 Author Posted May 31, 2016 While the new turbo parts starting to dribble in, I rebuilt the engine and already have put it back into the frame. What I forgot to mention is that during the repairs on the cracked header I saw that the left 2 pipes were white and the other two were black. As I have twin boost compensation pipes (pitot pipes) on the bike, I suspected that these weren't doing exactly the same. So I used some T-s to connect them and went for a ride. No difference, at least the AFR stayed the same. But now I have the header back off again, the colors are identical on all 4 pipes! Quote
bruteforce Posted June 6, 2016 Author Posted June 6, 2016 With the bike all ready and awaiting fitment of the "new" used Subaru turbo, I took the turbine housing off as it needed a different orientation of the core in order to fit the oillines. Then I found this... Then after some difficult but friendly moments in communication, the seller (who genuinely didn't know) offered to exchange it for a brand new one for a little bit more money. Well chuffed! Need to do the physical exchange of turbos in the upcoming week. Quote
bruteforce Posted June 8, 2016 Author Posted June 8, 2016 (edited) Previous owner says 1,5bar but "with some lag" Edited June 8, 2016 by bruteforce Quote
bruteforce Posted June 11, 2016 Author Posted June 11, 2016 TD05-16G (Subaru Impreza WRX) buddy is tack welding the lot, then take everything off for final welding. Weather permitting I expect to be riding the beast with "Big Boys" turbo in the coming week. 1 Quote
bruteforce Posted June 17, 2016 Author Posted June 17, 2016 (edited) Almost ready to run. You know the feeling? You've just spent a lot of money on your bike but it still looks exactly the same as before.... Self-tapping screw on the airfilter is for an additional don't-loose-me bracket. Edited June 18, 2016 by bruteforce 6 Quote
bruteforce Posted June 18, 2016 Author Posted June 18, 2016 (edited) Had to make a banjo bolt for the oilfeed as no-one in my town could deliver one. The braided oil return hose was now an inch too short ofcourse. As I kept puncturing my fingers on the ends of the thing I found it wise to just fit a simple fuel hose. After a bit of fiddling the wastegate actuator and oil catchtank are no longer fighting over the same space. Painted top of K&N filter black as it was corroded from lying in a damp shed. First startup, burning some oil off, turbo turns faster than the vid shows Now, if it would finally STOP RAINING it would be time to go for a spin... Edited June 18, 2016 by bruteforce 2 Quote
bruteforce Posted June 19, 2016 Author Posted June 19, 2016 Weather was great today so I went out on the newly equipped bike. First some slow speed stretches with lots of stops to check the bike for trouble before opening up the throttle. It starts boosting at 4000 rpm and makes full boost at 6000 rpm. The actuator apparently is a 15psi one which came a bit as a surprise to me! When opening the throttle in 5th at 200kph it will still want to lift the front despite my weight hanging over the 'bars. On private roads ofcourse... TO DO: Slight oilleak from the left lower side, and I want to fit an extra crankcase breather to the filler cap position. And check all bolts etc. I LOVE this bike! 6 Quote
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.