EFI on Oil Boiler

[Duckndive]

Ok so some time ago i acquired some unfinished TBs From a GSXR 600 "think" that had been dismantled and had inlet stubs welded on the secondary butterflies have also been removed and the holes blanked off and as can be seen a new fuel rail fabricated I also have a matching plenum "not shown" but plan is N/A first 

So today i bolted them to a spare 1100 / 1200 Head which went quite easy as only the fuel rail holding them together 

So 1st job is to make some spacers and fix the TB.s together in a more rigid fashion .

I have some injectors on the way and will also have to make some insulating blocks for between head and TB,s ..

So TBC ... 

Edited August 18, 2025 by Duckndive
Added pic

[Gixer1460]

Looking good! Shame the TB's weren't gotten a bit closer to the head, bearing in mind the cam chain tunnel pinch point. But will follow as carbs are just soooo yesterday 

[Duckndive]

3 hours ago, Gixer1460 said:

Looking good! Shame the TB's weren't gotten a bit closer to the head, bearing in mind the cam chain tunnel pinch point. But will follow as carbs are just soooo yesterday 

Bizarrely the Air inlet face off the TBs are 5mm closer to the head than the air inlet face of the RS40's on my 1340 motor ...

[Gixer1460]

Understandable with all the throttle bracketry on the RS's - just looks like space to be trimmed to TB's & fuel rail? Immaterial anyway - just get it making noise first!

[Duckndive]

So As Mr Suzuki San uses 5mm Cap Screws to hold the bodies together a trip to local eng merchant for a 6.5mm Long Series Drill and Some 6mm Threaded Rod and Viola Holes opened up to 6.5mm 

[Duckndive]

Lost count of the no times i had the bodies on and off getting the spacing right using washers as temp spacers 

But finally got them were i was happy and importantly the bolts into the head could be easily started 

Even the Plenum fits nice and snug 

Waiting on Injectors now so i can make fuel rail spacers...

Best make a list of parts need while waiting and think about an ECU 

[R1guy]

On 8/18/2025 at 8:53 PM, Duckndive said:

Ok so some time ago i acquired some unfinished TBs From a GSXR 600 "think" that had been dismantled and had inlet stubs welded on the secondary butterflies have also been removed and the holes blanked off and as can be seen a new fuel rail fabricated I also have a matching plenum "not shown" but plan is N/A first 

So today i bolted them to a spare 1100 / 1200 Head which went quite easy as only the fuel rail holding them together 

So 1st job is to make some spacers and fix the TB.s together in a more rigid fashion .

I have some injectors on the way and will also have to make some insulating blocks for between head and TB,s ..

So TBC ... 

is there any reason / advantage to have the inlet stubs welded on, over using rubber boots? ( other than being trick?)

[Duckndive]

6 minutes ago, R1guy said:

is there any reason / advantage to have the inlet stubs welded on, over using rubber boots? ( other than being trick?)

i bought them like it 

Potentially its a disadvantage with heat transfer from head so i plan on fitting some insulation blocks 

[R1guy]

Ta. Not knocking it, just trying to understand pros and cons 

[rodneya]

What are you planning on using to control the injectors?

[Duckndive]

11 hours ago, rodneya said:

What are you planning on using to control the injectors?

Looking at various ECU,s ......... MaxxECU looks favorite at moment as it seems more user friendly to a numpty than others 

[Duckndive]

Injectors arrived waiting on 11mm to 14mm adapters for the fuel rail now ....

[Jdeac]

This setup used to belong to me.

It was made to suit siemens dekka 660 short injectors if that helps you in anyway.

And if memory serves me right they might be gsx1400 bodies. But dont hold me to that

[Duckndive]

43 minutes ago, Jdeac said:

This setup used to belong to me.

It was made to suit siemens dekka 660 short injectors if that helps you in anyway.

And if memory serves me right they might be gsx1400 bodies. But dont hold me to that

There early gsxr 1000 bodies and use Busa or Blackbird type injectors .  I now have the injector adaptor,s for the fuel rail ...and when the tame machinist has some time the fuel rail holes will modified to suit ...

[ColinH]

Looking good there. Interesting discussion around heat soak. As I’m awkward and Building draw through throttle body but fuel in runners I’m a little concerned on same issue.

I don’t have much space with Turbo in the area so was going to bolt straight to head. Hadn’t though of small spacers for insulating heat from head.

Thanks for the idea at just the right time. 

[Duckndive]

On 12/14/2025 at 6:10 AM, ColinH said:

Looking good there. Interesting discussion around heat soak. As I’m awkward and Building draw through throttle body but fuel in runners I’m a little concerned on same issue.

I don’t have much space with Turbo in the area so was going to bolt straight to head. Hadn’t though of small spacers for insulating heat from head.

Thanks for the idea at just the right time. 

TBH in hindsight i don't think heat soak will be a major issue unlike on carbs which have float bowls etc  

[Gixer1460]

2 hours ago, Duckndive said:

TBH in hindsight i don't think heat soak will be a major issue unlike on carbs which have float bowls etc  

'Tis true, injectors hold miniscule ammounts of fuel and fuel in rail is continually recirculated (providing its not a deadheaded system!) Most injectors also have wiggle room in the injector 'cup' and are isolated via o-ring so not a lot of direct heat transfer.

[ColinH]

6 hours ago, Duckndive said:

TBH in hindsight i don't think heat soak will be a major issue unlike on carbs which have float bowls etc  

 

4 hours ago, Gixer1460 said:

'Tis true, injectors hold miniscule ammounts of fuel and fuel in rail is continually recirculated (providing its not a deadheaded system!) Most injectors also have wiggle room in the injector 'cup' and are isolated via o-ring so not a lot of direct heat transfer.

Thanks for the insight gents, saves me a job. 

[TLRS]

Shirley there’s a reason many FI bikes have rubber mounted throttlebodies? Don’t think they do that on cars though. Maybe something to do with revs and vibration?

[Duckndive]

OK as waiting on a few bits for the outlaw decided to do a bit of CAD today and make some gaskets for the throttle bodies to go on Izzy..

Have done a few other small jobs on this so more pics later when I find them 

[Duckndive]

Unnecessary "at this stage" stock vacuum connections blocked off 

Jeff Delivered some cheep hole punches so finished the gaskets off and blocked the inlet side vacuum ports 

And the fuel rail after jonny1bump bored the holes to suit the LS Injector adaptors 

 

[Gixer1460]

31 minutes ago, Duckndive said:

Unnecessary "at this stage" stock vacuum connections blocked off 

Good place for MAP sensor port connections though ! 

[Duckndive]

Ok so had to assemble fuel rail & injectors on bench as not quite enough room to do in situ ..

No huge issues aside from fuel tap lands on fuel rail but i will need to sort a fuel return as well so another job for the list also need spacers for the Fuel rail to pull down on ...

I also tried the plenum and fits nice but will be N/A first...

So need to order bolts and some other ikle bits and ask 1bump nicely to make four spacers ... 

Back to the outlaw and sell some more bits  

Edited April 30 by Duckndive

[Duckndive]

So while waiting on stuff to arrive removed the fuel gauge,s from the tank and reversed the tap so it clears the fuel rail and allows tank to sit correctly popped a stick coil on and they clear tank as well so hopefully will be able use the fuel gauge fitting hole for a fuel return 

[Duckndive]

Removed the fuel gauge sender and drilled hole for weld on AN6 fitting 

And after sussing the knack to get tank on with stick coil in place added hose fitting and viola fuel return sorted with a Female / Male 90 i will be able to run line over the cover for a more stealthy look 

Waiting on pingel tank adaptor and couple other bits for the feed side now ..