01/06/06
It's been a long time since I updated this page and a long time since I worked on the bike. There have been many interuptions and distractions and now I find myself in the middle of a mild winter longing to ride my bike. I only have 3 months give or take to get it done. I've moved away from my ghetto ways slightly and in the interest of riding when the ice melts, I've ordered all of the parts I still need via the aftermarket instead of eBay or salvage. My budget is still slight so there still a lot of work to do. I'm going to try and contribute something to my Wiki here at least once every day or two so stay tuned.
After sitting and staring at a box of the VEMS stuff I ordered for months now I'm finally ready to start things.
The project is completely ghetto and unique partly due to my budget and partly due to my dislike for anything mainstream. Budget is what led me to buy the VEMS in the first place...well that and the fact that I love AVR microcontrollers.
I must have been hit in the head or something because I decided to put a turbo on my motorcycle and crank it up to 300HP. I researched it for a long time and I didn't agree with the normal, 'kit' install method, which relies on complicated modifications to make the original ECU work (electronics boxes, extra injectors, etc). Instead I decided to buck tradition and do everything in a way unlike ever done before.
I'm starting with a 2001 Suzuki Hayabusa with low milage. Most of the parts I have for this project have been accumulated via various sales, eBay, salvage, etc.
There's still some fabrication to go at this point but soon I'll start installing the ECU.
Subsystems - please help with setup and configuration:
- MembersPage/DTechnologies/Hayabusa/Trigger my biggest challenge is to make the original crank and cam triggers work
- MembersPage/DTechnologies/Hayabusa/GearSensor Gear position switch interface brainstorming
- MembersPage/DTechnologies/Hayabusa/BoostControl Electronic Boost controller brainstorming
- MembersPage/DTechnologies/Hayabusa/Config Config file(s) and brainstorming to date.
- MembersPage/DTechnologies/Hayabusa/IdleControl Planning and develpment of idle control.
Engine has been modified as follows:
- 60lb. valve springs from Carpenter Racing
- 0.080" cylinder base spacer (reduce compression to aprox 8.7 : 1) courtesy of Falicon
- High volume oil pump gear from Schnitz Racing
- High pressure oil relief valve from Schnitz Racing (gear and valve combine to create an oil pressure of about 175psi)
- Modified low profile oil pan (special thanks to Terry McIntosh of McIntosh Machine)
- MPS Racing polution control block off plates
- MPS Racing clutch kit w/ high pressure clutch springs
- MSD blaster EDIS coil pack
- Custom spark plug wires (MSD 8.5mm Super Conductor, Pro boots, EDIS connectors from Magnecor)
- NGK Iridium CR9 spark plugs (Thanks to the local NGK rep for hooking me up)
Fuel system - almost completely custom:
- Walbo in line fuel pump
- Aeromotive fuel pressure regulator
- Professional Products fuel filter
- Injectors salvaged from a Honda S2000 (thanks to the guys at suzukihayabusa.org for the hook up)
The turbo is a T3 Garrett I picked up second hand for $200. It's a little rough around the edges but shaft movement is perfect.
I've built the exhaust manifold myself out of scrap, tube from the original headers, and some mandrel bends from the local autoparts shop.
Thanks to eBay, I've found a slightly dinged up intercooler from a wrecked Audi TT. It doesn't fit great but on the road to 300HP, I'll need an intercooler so I'll make it work.
Some things I'd like to implement if possible:
- Electronic wastegate/boost control - of course
- Connect ECU to gear position sensor - useful for BoostControl
- I haven't found a wastegate yet but I'm trying to find something inexpensive that I can use the ECU to control the boost. I have some ideas to try some unconventional things with that sa well.
- Electronic blow off valve control. Why do you need this? simple BOV-s work very well AFAIK
- Output to control air shifter (automatic upshift)
- Automatic wheelie control: reduce boost/retard ignition when front wheel comes off the ground. This uses similar actuation as a tractioncontrol system would (and somewhat similar to ALS), but input signal is different:
- This system will be triggered by a simple microswitch which is triggered when front forks extend fully (zero spring compression).
ECU Mounting
- I've decided to mount the ECU inside the battery box which has been relocated to the swing arm. I'm concerned about vibration damaging the ECU. How resiliant is the 3.2 to vibration? Being mounted to the swing arm, it will see vibration straight from the wheel with no suspension in between. I plan on mounting the housing using MSD rubber stand-offs to help protect it from vibration. Is there anything else I can do?
- honestly, we have little experience. v3.2 is made with SMD components, and found to survive in racecars with serious vibrations. If the TO220 components are clamped, and ECM mounted with some dampener, it should survive for long.