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Project FZR150 Bucket race motor

Discussion in 'Other Projects - Other Bikes (non 250's)' started by gregt, Aug 14, 2016.

  1. gregt

    gregt Well-Known Member Premium Member

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    Well, this project isn't dead. Nor am I. Post major surgery - replumbed and with electronic ignition fitted - I'm back into work.
    Had a backlog of engines to do and to get myself moving i pulled out and restored my old F3 EX500 Kawasaki. That's done and running so it's work on the little Yam while waiting for engine parts for an RC30 and a race CBR600.

    Pipes are made - short, stepped and separate. Small alloy mufflers fitted. Hanging under the motor there's sfa to hang the mufflers on - RHS is hung off the bottom two screws on the clutch cover, LHS off the rear waterpump screw. Not ideal but the mufflers are very light.
    Bullet has been bitten and a non exup ignition box ordered from Alibaba. None of the 3 boxes I scored gave a spark.
    In-frame box tank has been fabricated in 16G alloy and is away for stage 1 welding. When it's done, I'll make the fittings and mounts.
    Clutch and throttle cables sourced, bars generally sorted - nylon ends made, grips fitted etc.
    Instruments to be mounted along with the OE top fairing I bought.

    Still a long way to go - but progress is being made.
     
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  2. ruckusman

    ruckusman Well-Known Member Premium Member Dirty Wheel Club

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    Glad to see you back and at it
     
  3. gregt

    gregt Well-Known Member Premium Member

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    Okay - fairing mounts are done,instrument mount included, Sorting the wiring that has to remain on the instrument pack,
    By my reckoning it's five wires to a plug.

    Power in - to tacho,oil light and neutral light,
    Earth - tacho.
    Grey from coils for tacho.
    Power out to neutral switch
    Power out to oil sender unit.

    Which raises a small problem. I've used the early sump with filter underneath - and an oil level sender...
    I really want a pressure warning so need the later sender in circuit - but where to put it ?

    My answer at this point is going to have to be make up a double decker fitting for the banjo bolt on the front of the cases.
    This is on the end of a gallery direct from the pump - and of course feeds the head galleries.
    It's out of the way if it goes down the road and I have rubber covers here for those fittings.

    I must find out from the wife how she manages pics on this computer - it's hers - and get some current pics up.
     
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  4. gregt

    gregt Well-Known Member Premium Member

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    Fitting duly made. Found a suitable piece of hex steel in the scrap box - a long nut which started life as a Norton twin head fastener. Throw nothing away...
    The penny dropped also that I'd forgotten the temp gauge. It uses the common power feed and earth but has it's own wire to the sender unit. So six wires in the plug.
    Probably make up a stand for the thing tomorrow. Take some pics too. If we get a good still day, there's a seat to paint...
     
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  5. gregt

    gregt Well-Known Member Premium Member

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    This is where it stands now. Tank away for welding, loom to make up. Ignition still to arrive.
    Black wasn't my preference. The top fairing looked silver/grey on trademe - and the tinted screen, wasn't...Still, it was cheapish.
    Bear in mind I got a bare frame with brakes and bars - plus a chopped about stock rear subframe with a horrible rough fiberglass seat. But free.
     
  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Got any pics Greg?
     
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  7. gregt

    gregt Well-Known Member Premium Member

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    Yes - but the site won't accept them. My camera works on an unsupported browser. Pics have to be put on another computer, edited and put on a flash drive for transfer to this computer....The site accepts them in that it gets to 100% indication - then informs me there is a problem and rejects them.
    I can't expect your hosting service to keep accomodating out of date software.
    So further updates can be viewed on Kiwibiker forum. Bucket racing section. The sensible twin thread.

    From an FZR250 owner/tuner's point of view, the only remaining bit of useful info would be a dyno chart...and that is still some way away.
     
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  8. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Consider uploading pictures to imgur.com after editing their size down. Then all you have to do is copy and paste the link
     
  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    bucket 3.JPG bucket 1.JPG bucket 2.JPG
     
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  10. Andych

    Andych Well-Known Member Premium Member

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    Very nice work so far... It will be nice to hear it run :)
     
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  11. gregt

    gregt Well-Known Member Premium Member

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    Thank you very hard for posting that - and yes, I'd also like to hear it run.

    I have an electrical question for the brains trust.
    I've received a new 2KR ignitor box - ex Alibaba...and have completed the wiring.
    All the appropriate lights come on, even the temp gauge moves...But the fuel pump doesn't make a sound.

    Ny understanding - and the way I've wired it - is that the pump gets power from the relay - which is triggered
    by the blue wire from the ignitor. It bench tests fine, power and earth both connected, flick power to the blue wire in
    and away it goes.
    There's power going in to the ignitor but no readout of power available at the blue wire connection.

    Is there any other condition to be met in order to get power to the pump ? It actually has it's own earth FYI.

    I haven't yet tested for spark as the correct plug caps are arriving next week. If it sparks but won't work the pump as designed
    I can live with that. Simply eliminate the relay so the pump goes live when the power is switched on
     
  12. gregt

    gregt Well-Known Member Premium Member

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    Got a spark...So it's rewire the fuel pump to eliminate the relay.
    The pump I know is pressure sensitive so will only run when it has to.

    So there you go. A new 2KR ignitor ex China with a problem.

    Next job is to convert the semi downdraft NSR carbs to full downdraft mode.
    I've got an idea how it'll be done, this could change as is uisual, LOL....
     
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