EFI?

[carsounds_dan]

Hi all,
been looking into this recently since I have a spare engine.. Whats the deal with fuel injection and what would be required to change a zxr to fuel injection.
Obviously I'll need throttle bodies and injectors, a EFI controller and probably some new sensors. but where are the injectors mounted? Are they mounted after the butterflys within the throttle bodies? or do I have to create a hole in the inlet port for them to sit in?
I take it if I use MegaSquirt that I can use the standard Coolant Temp Sensor? also the TPS on the throttle bodies? the original Coils? the original Pickup coil/Crank Sensor from the engine? Fuel Pump? where would I send the return feed?
cheers
Dan

[Scott221]

Mate, it would be easier and more than likely cheaper just to buy a bike with FI. Or, buy an engine with fuel injection and try and cram it in.

Your looking at:
ECU
All the sensors (oxygn sensors throttle position engine speed sensor etc etc)
Mod the loom
possibly new camshaft
and youd more than likely want a ram air system on there.
not to mention all the kit, injectors arent cheap either!


The injectors are mounted in the intake manifold so that they spray fuel directly at the intake valves. Its do-able, and a fuel injected zxr would be very very very nice, but lets be realistic.

[carsounds_dan]

well i'm wondering if theres a model that has the injectors mounted to the bottom of the injectors so it's just one big lot to mount to the engine?
I know about the sensors but getting them isnt a problem at all. Nor is moding the loom and the TPS is usually part of a throttle body setup anyway.
The only thing I'm a bit confused about is where to go with the ECU, go for MegaSquirt or find an alternative? is there an alternative?
Time isnt a problem and money isnt, it's just working what ECU's are available out there... and what the benefits would be? obviously a little bit of performance but I was thinking more about the whole fuel economy thing? would it actually make much of a difference.
cheers
dan

[Gemini]

i aint being funny, but kawasaki never saw the point of giving the zed fuel injection so why bother?

the factory R1's that were used on the IOM TT had their EFI taken off and carbs bolted on cuz the riders said they were toad!

and as far as i hear, if you are gonna buy an R1 as an example, then u want the carb model one!

thats just my opinion though

gem

[Ballsout Racing]

There's a Race FI ZXR400 for sale on motoforum at the moment. The chap, Alec, doesn't get on the www much. He did most of the conversion engineering with much guidance from Dynotech in Basingstoke. Alec made the inlet manifolds to take the injectors etc which was the most expensive part, IIRC he said he would supply them for £600, everthing else was from a ZX6r off ebay for relatively little money. If you're serious speak to Andy or Keith at Dynotech on 01256 881711. They have all the mapping info

[Gemini]

thats all well and good for the track where if several thousand pounds gets u an extra second a lap faster but on the road, i personally feelmost engine mods are not financially viable as u cannot ride a road bike fast enough to notice these nominal advances

gem

[Northern ANdy]

Best thing to do would be to patch a FI bikes EMU into the zxr, take all the sensors over with it too, but you are looking at a momoth task, just one tiny part of it eg. some way of calibrating TPS represents huge amounts of work. Its a good idea and would be a mint project but the shopping list is monsterous as is the time demand and brain strain. Should be able to get away without a massive array of sensors, eg. just TPS, crank position, lambda but if you wanted to go nuts you could add more sensors than soft mick

[Ballsout Racing]

thats all well and good for the track where if several thousand pounds gets u an extra second a lap faster but on the road, i personally feelmost engine mods are not financially viable as u cannot ride a road bike fast enough to notice these nominal advances

gem

Actually, it didn't make a difference to lap times. bhp increase was less than one, but it gave a lot more midrane and drivability.
And it would cost approx £2k if you ride in ride out. I would assume the person asking would want to do most of it themselves. As I say the expensive bit is getting the inlet manifolds, if they're an enginneer the cost would be a few lumps of ally and some machining time, the rest was apparently purchased from ebay for less than £100 notes, so all in all it could be relatively inexpensive, Dynotech have already got maps, so just a little dyno time with them would see it set up.

When you consider how much people spent on a set of flatslides and dyno setup time, it's actually quite reasonable, but that is subjective of course.

[carsounds_dan]

I have a set of flatsides and ram airbox that will go up forsale. I've been looking and MegaSquirt can be calibrated using an OE TPS and all other sensors in a similar way.. just wondering what throttle bodies would do the job?
cheers
dan

[superman]

good god... if it aint broke, dont fix it!!!!!!

[rene]

^^^ wheres the fun in that! classic honda/CBRrr rider...

not to sure what size you'd actually want to go for but somthing like the 636 system would propably work can pick them up cheap as chips as well

[deviant]

We'll you're all a miserable lot. Of course kawasaki didn't put it on a ZXR...but then they designed the bike in 1990ish and didn't change it much after. FI wasn't realistic in the early 90's.

It will be difficult, but it has been done. If you want to do it as a project on a spare engine then go for it.

TBH I don't think it would be that expensive to put a system together - modding bits from other bikes, etc. But it would take a hell of a long time to get it working how you wanted. But I expect you'd learn a hell of a lot from it.

If you want a proper challenge, I was talking to someone last week on another forum about the possibility of putting a two stroke top end onto a 4T bottom end, with a blower to perform the scavenging that would be done by crankcase pressurisation in a conventional 2T, and using direct fuel injection. First person to build a 120hp 2T ZXR400 wins a cookie.

[tobomoto]

chocolate chip?

[deviant]

frankly if you actually went and did what I suggested, you could have whatever variety of cookie you wanted

[rene]

i could live with the FI system but milling your own head ect is a little above my IQ level..even if it is 2t.

Just out of intrest how would you fit the exhurst hole below the intake? after all its solid engine case...or are you going to extend the barrels with the new head? and would you use powervalves or just have a shitty bottom end?

That sounds like a killer project any way