XJ700 *EFI* The holy sh*t it is fast now mod!

Hello all I've been trolling the forums for a few months and now it is time to start the ol build thread cause I have looked on here and only a couple people have attempted the fuel injection modification.

A little background on me I have a 450hp 1990 Toyota Supra with a 1JZ with a Holset HE351VE turbo running Megasquirt 2 that I daily drive and It is time to move to something to a smaller scale for a hobby and now living in New Mexico with always great riding weather.

So it begins I own a 81 XJ650 my neighbor gave to me a few months back in pretty bad condition but you can beat free right? Well once I moved all the way from Virginia to New Mexico (Air Force) I found a 85 XJ700 in El Paso, TX for 450 bucks. So I drive down there the guy has to use a battery charger just to start it. So I strap down to the trailer and happily drive back to Alamogordo, NM with my new buy. So I got it off the trailer inspected the battery and marked on the side was 2001 install date so I went to Walmart picked up a new battery and a few items and had the bike running by the end of the day. The bike pretty much needs everything looked over because it looks like it has been sitting for awhile so on to the build.

Here is the list of parts for the fuel injection.

Microsquirt - $400
GM IAT and CLT sensors - $30
GM 1-Bar map - $20
03 GSXR 600 throttle bodies - $60
03 GSXR throttle - $45
3" 36-1 Trigger wheel - $20
Innovate LC-1 Wideband - $139
2009 Honda Rincon Fuel Pump - $95
420a Coil Pack (Dodge Neon 2.0 about 45k volts) - $0
2 relays and 1 fuse holder - $10
8mm Summit racing wires - $45
Intake - $25
Filters - $30
Total - $919
Now mind you this total doesn't include tools or wire and connectors and other items I already owned.

Going to replace all lights with LEDs and a HID headlight to keep electrical load as low as possible.

I plan on replacing all broken or worn parts which is a lot. New tires, brake lines, paint, and etc.


Now for some random photos

 

Re: 85 XJ700 Fuel Injection Build

Look's like you got a hellova deal for $450. Seems to be in good shape, mine was dropped on both sides :x by the PO but ran good. This looks to be an interesting build, I'll keep watching and wish you well. BTW If I didn't say it before: Welcome to the site. :wink:

 

Re: 85 XJ700 Fuel Injection Build

Subscribed! 8)

 

Re: 85 XJ700 Fuel Injection Build

Welcome to the site. Looks like a great deal you got there. Very intrested in seeing this build come together.

 

Re: 85 XJ700 Fuel Injection Build

Not only is $450.00 a steal, but look at what can be re-couped by selling the stock carbs, air box, etc.

 

Re: 85 XJ700 Fuel Injection Build

Yeah the carbs will be up for sale soon. They ran decently after I run some good gas through them and seem to be in a good shape and I also have a basic rebuild kit to go with them. The air box got a small crack during removal but nothing to stop its function.


To add I found a Hayabua fuel pump for 160 bucks.

 

Re: 85 XJ700 Fuel Injection Build

Welcome!! You did see SQLguy 's thread/build ??

And don't forget the rear brake check.

 

Re: 85 XJ700 Fuel Injection Build

I think the next old bike I get I am going to try out mega squirt. It sounds like a lot of work but I like the idea. I just helped pull one of my old roomates 325 e30 motors witch is running megasquirt 1. I hope you post a lot of pictures!

 

Re: 85 XJ700 Fuel Injection Build

I'll have exactly everything you need to do EFI one of these XJs listed once I am done. I'll even share out the maps so all you will need to do is install and go have fun =)


I already have all brand new brake pads/shoes. The brake system on a motorcycle is the number one priority for me.


Timing map based off what the factory service manual provided. (Map is subject to change)



P.S. My tools will be delivered tomorrow.

 

Re: 85 XJ700 Fuel Injection Build

Update time.

Alright I order 80% of my parts in the past two days.

Here is a picture of my painted tank and rear fender. I have the GSXR 600 throttle bodies installed and made a 12-1 trigger wheel for the crank.

I also picked up a 2009 Honda Rincon fuel pump. The pump is self regulated to 43psi and has a built in surge tank surrounding the fuel pump and is only 140 dollars new!

 

Re: 85 XJ700 Fuel Injection Build

Lookin' good. How did you make the trigger wheel?

 

Re: 85 XJ700 Fuel Injection Build

I made a template out of some aluminum, using a 12 tooth trigger wheel I have from a 1jz then drilled out the 12 holes. Then I just placed it on top of a piece of steel and drilled the holes. Then used a hole saw to cut it out.

 

Re: 85 XJ700 Fuel Injection Build

There's always someone that comes along and makes things look simple.LOL

 

Re: 85 XJ700 Fuel Injection Build

Do the GSXR 600 throttle bodies rack mount directly to the OEM carb manifolds or do you also need to mount the GSXR 600 manifolds (or...)?

 

Re: 85 XJ700 Fuel Injection Build

The throttle bodies silide in the stock boots with a little force

 

Re: 85 XJ700 Fuel Injection Build

your getting there looks good. Hopefully it turns out good and runs great. The only thing that would concern me is you better have a spotless tank and a great fuel filter we know how injectors do not like dirt. But im sure the filter for injection is a lot better then those little filters we usually use

 

Re: 85 XJ700 Fuel Injection Build

Well here is some minor updates.
I have received more parts in the past few days.

HID kit
tires
some seals
better condition guages
Air filters
GSXR 600 throttle control 2003

I rebuilt the front forks and took off the triple tree and repacked the bearings.

HID light installed in the stock housing. Lens needs some cleaning and adjustment though.



Had to modify the stock throttle cable holders so I could use the stock GSXR 600 throttle cables.



Here are my new pods installed.




New Dunlop D404 tires.


My XJ650


And random pictures of the garage and motorcycle.

 

Re: 85 XJ700 Fuel Injection Build

Time for another update.


Fixed my broken shifter. The limiter on the shifter was broke. Replaced it and it shifts like it should now.

New tires mounted and balanced.

Installed a 130db horn. Very loud!

LED taillight installed with license plate bracket I made. This taillight automatically flashes when you hit the brakes.

I am waiting on the microsquirt and fuel pump to arrive along with brakelines.

I also ordered turn signal lights with reg bulbs so I can retain the stock flasher. As you can see in the pictures below I am using the LED mirrors and the amber LED lights in the taillight as running lights to keep power usage to a min during normal operation.

Also ordered some 194 LEDs to replace the 10 bulbs in the gauge clusters.

 

Re: 85 XJ700 Fuel Injection Build

Cant wait to see how it runs and what kind of mileage it gets.

 

Re: 85 XJ700 Fuel Injection Build

extremely interesting keep it up!

 

Re: 85 XJ700 Fuel Injection Build

UPDATE!!!!!!!!!!!!!!

Alright received the fuel pump and microsquirt today.

Also received my valve cover gasket from chacal!

So I mounted the fuel pump in I think is a great place for it.

The microsquirt is fitted up under the tank and I laid the wires out and just figuring out where everything is going to be placed.

I made a few plug wires. I found a trick is to heat the boot up with a heatgun to get the wire through easier.

So a few steps getting closer to firing this engine up.



420a coil pack with summit 8mm wires I made.


Fuel pump way down there.




Microsquirt!

 

Re: 85 XJ700 Fuel Injection Build

Shouldn't be long now. Cant wait to hear how it turns out

 

Re: 85 XJ700 Fuel Injection Build

very nice work im following this closely!

best of luck on the project! though it seems you dont need that much

 

Re: 85 XJ700 Fuel Injection Build

what year gsxr did those come off of, im doing the same thing to a 750 for my senior design project?

 

Re: 85 XJ700 Fuel Injection Build

2003 GSXR 600

 

Re: 85 XJ700 Fuel Injection Build

good deal, we are about to start assembly pretty soon, after i get everything dialed in, im hoping to get a turbo on it as well.

 

Re: 85 XJ700 Fuel Injection Build

could you take some more pictures of your ignition system and what components you used? thats the only area right now thats giving me trouble

 

Re: 85 XJ700 Fuel Injection Build

Well really not much pictures for the ignition system. just a coil and trigger wheel.

I'll be using a 420A ignition coil (dodge neon coil, very reliable coil).
Along with a 3" 36-1 trigger wheel using one of the stock VR (variable reluctor) sensors. The trigger wheel will be mounted in the location of the stock trigger wheel.

If you have anymore questions just ask. If you have a lot of questions PM me or keep them to one post if you don't mind. I would like to keep my build thread on track.

 

Re: 85 XJ700 Fuel Injection Build

this.is.epic!!!

 

Re: 85 XJ700 Fuel Injection Build

It runs.

Now you will have to wait for a update.......

 

Re: 85 XJ700 Fuel Injection Build

that's a good sign now all the fine tuning looking forward to the update

 

Re: 85 XJ700 Fuel Injection Build

Such a good build. I ran into this today, wireless tunning. This is the first of it I have heard about.

http://www.youtube.com/watch?v=xdqYTsWV ... re=related

 

Re: 85 XJ700 Fuel Injection Build

Yeah the updates will be coming a bit slow over the next week due to work schedule.

But the engine screams! Revs way faster then it did with the carbs.

 

Re: 85 XJ700 Fuel Injection Build

Looking great.

Can I ask why you chose the GSX throttle bodies in particular?
My 750 has 32mm throttle bodies (28 if you consider the venturi restriction).
The GSXR600 is 38mm or so? Considering the valve and port size wouldn't getting a perfectly smooth tune on very small to medium throttle openings be a compromise?

I am doing a similar project, and have an R6 throttle setup that I bought for the injectors, but will be staying with a smaller dia throttle body set up.

What fuel pump have you decided to run with? The lowest current draw I can find to do the job still uses close to 6 amps.

 

Re: 85 XJ700 Fuel Injection Build

couple q's.. how much did it cost, and how much would you charge for a pretty much all the work done package? would love this on my bike...

 

Re: 85 XJ700 Fuel Injection Build

Stunning.. Thanks for sharing. Great work

Any chance if some indication of costs?

Thanks

 

Re: 85 XJ700 Fuel Injection Build

...and a DIY step-by-step including complete part descriptions would be cool too!

 

Re: 85 XJ700 Fuel Injection Build

I'd love to do this to a 900 but I don't have the budget or time to make it happen

 

Re: 85 XJ700 Fuel Injection Build

Once I have this all done I'll put a lot more details up.

The reason I used GSXR 600 TBs is they are a direct fit and easy to make work.

Fuel pump is off a 675cc 2009 Honda Rincon.

The fuel injection side of things is around 1000 dollars to do. This all depends on what you can find at the time. This would be a bit tough to do as a kit or ready to install due to the fact of the some of the modifications done.

I had it running till the microsquirt failed. The engine revved extremely fast way faster and much more responsive then the carbs ever could.

 

Re: 85 XJ700 Fuel Injection Build

When you say this, do you mean that the idle was faster than with carbs?
Do you think that it revving up faster due to better response from the fuelly mod that it may be harder on the clutch action and modding to a heavier clutch might be needed?
Nicely documented build to this point, nice work!

 

Re: 85 XJ700 Fuel Injection Build

oh wow 1000, lol never mind so much, haha, i was thinking maybe parts would be 5-600..

 

Re: 85 XJ700 Fuel Injection Build

I don't think he did it for the cost factor. I think he did it to prove he could and to be different. I am curious what kind of gas mileage it gets

 

Re: 85 XJ700 Fuel Injection Build

I just hate carbs.

 

Re: 85 XJ700 Fuel Injection Build

Looking forward to the complete write-up. I thought you were going to use a 2000 Hayabusa fuel pump; is the Honda unit the same item or just happened to be more convenient? Any idea on why the MicroSquirt failure (or if any changes need to be made)?

 

Re: 85 XJ700 Fuel Injection Build

when you think about the price.. cr carbs cost about 800, so 200 more more fuel injection is nice

 

Re: 85 XJ700 Fuel Injection Build

The reason for the rencon pump is it outputs 43psi and has a built in surge tank and only costs 145 bucks new! Hayabusa pump seems to go for 200 bucks used and is over 500 bucks new.

I got the new Microsquirt today and it works great! Now I just need to install the wideband and finish the wiring.


Oh and this may be in the future! http://cgi.ebay.com/ebaymotors/ws/eBayI ... 103wt_1165

 

Re: 85 XJ700 Fuel Injection Build

Any pics or links on the rencon pump? Currently I will probably use a Nippondenso passenger car pump, cheap and common. But as my ideas have changed as the project evolves its good to see new potential solutions.

For the record, I am also doing an XJ750 with Microsquirt (module), but not on my current motor, on my one currently getting rebuilt. (have everything except pistons).

So what did you do to the poor Microsquirt unit?

 

Re: 85 XJ700 Fuel Injection Build





Injector drivers failed on the microsquirt.

 

Re: 85 XJ700 Fuel Injection Build

Installed the LC-1 today. The wideband sensor is installed in the right exhaust port.

I finished up the wiring and installed the two relays along with using alum foil around the high current wires (spark/fuel grounds). This shields any high current EMI from the lower current wires.

Well here is a bit longer video.





Intake I made. There are two separate intakes, makes the manifold pressure a lot more stable and easier to tune.





36-1 Trigger wheel in action.

 

Re: 85 XJ700 Fuel Injection Build

Rebuilt the front brake calipers tonight. Took a days worth of WD-40 soaking the brake calipers, a heat gun, and a slide hammer I made to pull the pistons out. Cleaned the calipers up and installed them back on the bike. Man takes forever to bleed the damn things. Going to finish bleeding them tomorrow.


Guess this build is just awesome for comments now. I bet no one else on here has a XJ running fuel injection and has a video.