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Project Fuel Injected Turbo FZR250, half

Discussion in 'Your 250cc Projects' started by Mike Green, May 9, 2020.

  1. Mike Green

    Mike Green Well-Known Member Premium Member

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    Little project that I've been working on for about 20 years now. In the middle of a rebuild after it dropped both exhaust valves in one cylinder.
    Engine is cylinders 3&4 only. 1&2 have been cut off and the end of the block and head blanked off. Originally ran an Ecotrons engine management system kit for a GPz250. The twin throttle body plugs straight in. The kits are very reasonably priced and after a bit of fiddling it was up and running.
    Due to suspected problems with the system I upgraded to a Link Atom engine management system. The turbocharger is an IHI RHB31A. The motor pulls boost from about 10000rpm. Best power to date was 32rwhp.
    One interesting part of this project has been finding all the differences between the original 2KR base motor and the new motor based on a 3LN FZR125 side1.jpg
     
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  2. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    You've got to be introduced to @gregt - also from your side of the pond and it seems imbued with the same sense of ingenuity

    Is is something in the water over there?

    WHOOPS, where are my manners

    Welcome

    :welcome:
     
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  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Welcome to the forum
    And nice work
     
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  4. Mike Green

    Mike Green Well-Known Member Premium Member

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    I've met Greg. Collected a couple of unused spare 3LN motors just before Christmas for my rebuild
     
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  5. Gen

    Gen Well-Known Member

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    Another saw handy motorcycle enthusiast , well done .
    How's the balance now ?
    Some build pics would be nice :thumb_ups:
     
  6. Brandon Otte

    Brandon Otte Well-Known Member

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    Hi, do you have a video on youtube of the 2 cylinder by any chance? I seem to recall seeing one.
     
  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Welcome and great work.
     
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  8. risky

    risky risky

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    welcome.
     
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  9. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  10. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Welcome back.
     
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  11. Brandon Otte

    Brandon Otte Well-Known Member

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    Is this yours?
     
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  12. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    And another

     
  13. Mike Green

    Mike Green Well-Known Member Premium Member

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    This one is with it fuel injected using the Ecotrons system but no turbo:
     
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  14. Mike Green

    Mike Green Well-Known Member Premium Member

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    The balance seems fine. Basically it is a 180degree twin. I've ridden it a few times and thought it was fine.

    The build has been documented on Kiwibiker starting about here: https://www.kiwibiker.co.nz/forums/showthread.php/68694-6/page51.

    The bike, #6, has had a couple of engines over time. Prior to the FZR engine I had Honda MB100 engines in it
     
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  15. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Welcome
     
  16. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I'm a bunch of pages into the kiwibiker thread - <DARTH VADER MODE> HMM, Impressive! </DARTH VADER MODE>
     
  17. Gen

    Gen Well-Known Member

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    hypo.jpg
    I also enjoy cutting tools & speed
     
  18. Mike Green

    Mike Green Well-Known Member Premium Member

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  19. Gen

    Gen Well-Known Member

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  20. Mike Green

    Mike Green Well-Known Member Premium Member

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    I cut the new cylinder head using my drop saw with a new 60T blade. Nervous to start with but it went through it like it was made for it. Made nice chips and everything. I love these little 250 Yamaha engines. Considering the abuse and lack of maintenance inflicted on them they seem to do OK. Pistons and bores have practically no wear. There is often a scorched bearing on the crank somewhere but the crank bearing surface has been good so far. The heads suffer a bit but I think that's down to the shops not wanting to work on them and riders simply not doing maintenance, valve clearances tighten up and valves and seats get overheated due to leakage. Every head I have looked at has had bad problems with valve sealing and often a dropped valve though I'm not sure what has been causing that. One possibility is the lack of spring pressure. Every spring I have checked is not at the correct installed height.
     
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