Project The Project Begins (ZZR250)

thats what i was hoping.. the ninja 300's is a returnless system, so i have to T peice between the fuel pump and the fuel rail. was hoping to just run the return line from the regulator to before the fuel filter. works perfect... just need another T-peice and oring clamps.. thanks linkin.

 

hey guys, today did a vid on stuff i've done so far,

(apologies in advance, not use to recording myself/voice and uploading it for everyone to see)



side not, i've had to buy another fuel pump as the one i bought was only 4psi when the 300's injectors need 43psi. so that should be here wednesday to continue with the fuel system, hopefully everything gets here in the next few days so i can get the wiring started.

 

received the fuel pump today.. tried fitting it.. with adaptors to 8mm its way to long. cant find the right adaptor at a 90 degree bend, so the good old aussie saying comes to mind. she'll be right mate. got something in mind for tomorrow to plumb it all up and make it look sweet if not tidy.. hell she'll look like a bloody mess but it will work.

 

update, worked the fuel plumbing out and the pump.. not happy with it but it will do.


top down view, like with the vid, there is a slight problem with fitment, had to lightly zip tie the fuel pipe to the left side frame, and sorted the problem with the coolant filter and zip tied that loosely just enough so that nothing is touching the flywheel of the throttlebodies


left side, fuel pump has a slight gap from the engine and sits under the throttle bodies, not what i was hoping for, and certainly not where i wanted it. but it fits and doesnt kink or bend the fuel lines.

right side


nothing is kinked or bent to badly as to reduce fuel flow, but i would suggest for those with bikes similar to mine, get a small fuel pump that does 43psi. or you can get the fuel pump seperately from ecotrons (price unknown)

everything looks good, tank still fits, just waiting on the relays and then i'll get cracking on the wiring.

 

leaving it as is for the moment till i get everything running nicely, then when i do the exhaust i'll be removing the airbox and fitting podfilters on it

 

good point but would have to tune it after the exhaust goes on as well and cant afford a custom exhaust just yet. so will have to wait till after i start working, so in the mean time i want to start with a base, i know it runs with carbs in standard format, (albeit rich and increased fuel consumption) so by just changing the throttle bodies and getting it running will show theory turned to reality, and then i tune to a base map so i have the bare minimum to work from. then change the exhaust/airbox tune it for performance and if something goes wrong i can go back to base with the base map and know it runs. then check where things went wrong, and build back up.

i also want to know what the efi does to this bike in its base format. i currently get 250km per 18l, i've heard of people getting up to 400km per 18l and with it being a grey import the ex250H-6 i havent got any actual documentation on it. so from what i know of the bike riding it for a few months and learning the bike, i want to know what a small mod like efi would do to it, specially being an old bike and unknown history before any more serious mods

i dont know if it will increase acceleration, give me some more top end revs, i just dont know, but gives me a starting point.

it also gives me a starting point for my end goal. i plan on getting a 300 engine to transfer into it while i'm rebuilding the 250 engine with 300 internals which will be a while (bank doesnt know i'm gonna do it so have to be nice to bank before it closes my accounts) which will total a few grand of R&D to give me a nice little bike to play with. kawaka should bring out a zzr300 to give a sports cruiser variant to the ninja300.

whats the fun in riding a bike that you didnt rebuild/mod/or needs no improvements... i could go out and buy a ninja300 or a cbr500rr or any other 300 to 650cc bike (lams bs) and be like everyone else or build up a zzr250 to whats still reliable but has enough go to play with and put a smile on my dial and some frowns to some 300 riders

 

thanks joker, it will be good to know about differences in preformance, specially going to a 300's TB, the difference between carbs/efi climate, airflow. will be good to know which is best.. saw the boys from MCM do a test on original airboxes vs pods, airboxes won because the car's wernt tuned for pods.. the zzr250's airbox is i believe is bigger then the 300's which should effect how the TB handle it.. damn big learning curve thats for sure..


i dont want to think about the design of a carbie, best i can do is understand how it works, let alone jetting, airflow, mixtures, to get which ever tune your going for... i was brought up on carbie V8's still didnt get into to design of em..
in someways the design of the efi TB are more simpler then the carbies, but the trade off is fine tuning the efi is alot more indepth then tuning carbs. changing float height, jets, flow rates would be easier then minute details of every input for the efi, temp air/engine, manifold pressure, throttle position choke/sub-throttle, (i know side track)

 

finally some more progress, all the parts i need are here,

got the relays working using the brake light power as a trigger switch for the relays as its constant 12v when the bike is turned on. so it runs power into the junction box to 10a fuse to a split off of brake light, triggers for the 2 relays. and cause it got dark fast i'm doing the wiring for the power in on the ecu + injectors inside and completing more of the power side of the wiring tomorrow when its light out and then i'll do a power on of the ecu and connect it to the laptop do a vid of it, then wire up the sensors and should be close to a dry start.

side note, would of had more done today but when your trying to find a trigger source from a junction box, work out fuses (will need secondary fuse box $10 at SCA) it drags out the day...

would suggest if people arnt all that familiar with wiring to just buy the harness/ecu and other parts from ecotrons, as doing this without a plug and play harness is a steep learning curve and running back and forth between different wiring diagrams is a toughy if you dont know what your looking at. but it is fun...

will try to run through a proper vid of the wiring when the ecu powers up for the first time. giving some idea of what i did and how i screwed up;D

 

sorry no update yet, bought the wrong adapter (stay away from CH340 usb to rs232 adaptors) so i'm going to look for either another adaptor tomorrow or goto the recycle shop and find an old computer for cheap that has the rs232 plug. >.< should have the bike running by now, but with work starting on thursday, i will only get to play in the arvo's so hopefully a vid of the ecu starting up (it actually starts up now, just cant connect to the lappy) and then get sorted with the sensors, but everything else is fine...

todo list
sensors connected
calibrating sensors
test fuel system
double check connections
double check settings in the ecu
start the bike.

 

some good news, got another usb to serial adaptor from jaycar, the laptop picked it up with out a problem, and for my test i had wired up the TPS but ofcause had it backwards, but it works..

tomorrow after work i will get stuck into the wiring finish off the sensors and continue on with my list.
and will have a vid/pics on it when its all wired up and see if it starts