My Take On Fuel Injection (XJ650 Turbo)

Hi there i dont post much on this site i kinda just look around and learn so i bought this 82 xj650 about a year ago for 200$ needed alot of work so i got it running and rode it for about 2 months and then i started cutting it up. Chopped it up and got it done right before riding season started and rode it all summer and loved this bike but i got very bored and want more power so heres the plan.

82 XJ650 stock engine-24,000miles
custom built turbo kit by me
TD05 turbo from a DSM
38mm wategate 6psi spring (to start with)
XJ650 turbo oil pump and oil pan
XJ650 turbo air box
RFL BOV
microsqurit
ITB's for a unknown bike but it has 240cc injectors
Stock intake boots modded to fit bigger ITB
GM-3bar map sensor
GM-intake temp and coolent temp sensor
99 ford xr2 coil pack
36-1 trigger wheel using stock vr sensor
2009 Honda Rincon Fuel Pump
Barnett Clutch Kit

The day i picked it up


Started working on getting it running



Stared the chopping




then on to paint






Started to get it back together





Mid season





And where i am at tonight


CLT sensor

Microsqurit

modded coil to bolt to stock valve cover bolts (with longer bolts)

this just shows where i tapped for turbo oil feed








Here are some vids of me making sure the oiling stuff works this is running on the stock carbs

 

Very nice build but not being one to be a naysayer, let me give yo u a couple of "heads-up's".

The stock engine lacks a LOT of mods that were done to the turbo engine for strength like forged pistons, dual pumps and a few other things, the most important being a stronger head to handle the boost.

I'd caution you on that stock head. You should be ok as long as you don't reach too high for massive boost numbers. I've got mine set to 18psi and instead of using the wastegate with it's preset release, I shimmed my BOF or pressure relief valve to open at 20-21psi and I employ a boost controller which I have set to 18psi.

You've done a fantastic job though and don't want to take anything away from a really nice build. Did you fab the exhaust manifold yourself or was that a shelf item?

Definitely keep us posted on your progress. I'll be very interested to see how your EFI system works once you have it running.

jeff

 

Thanks Jeff is yours a factory turbo bike ? If not could you post up some pics of it. And yes I made the manifold

 

i have a temperature probe jb welded to the cam chain tunnel right about where your coils are and 230 is common at a red light and i've seen 250, are the coils ok with that?
moving it drops right to 180, 190

 

Yup, a factory turbo so it looks just like every other silver/red 1982 turbo bike out there....all 1000 or so of them that left of the original 5000.

I have been giving some serious thought though to maybe adding turbocharged induction onto a normally apirated bike though.....just need the right candidate, a fist full of cash and most hard to come by, the time. That's why I'm cuious about the EFI...I don't know very much about the microsquirt system but want to learn how it operates, what the confines are and how to and how much there is in the way of adjustments.

jeff

 

jeff im not to close with megatune yet but if you do just take your time and research alot lol

 

I'm in the process of building a microsquirt EFI right now myself.

Your throttle bodies are of a GSXR 750 or 1000.....I had some lengthy discussion with a more experienced conversion guy and he convinced me to switch to a set off a GSXR 600 which will give me better low end behavior and will still have no trouble giving me all the airflow and fuel I can use.
The turbo may make it even more difficult to tune for a more rideable low end I would think.

How much power does the fuel pump draw?

@ Jeff; I have been reading and reading all about the microsquirt. You can adjust everything you can imagine and then get creative with components and adjust some more. After a somewhat insomniac last evening, I can tell you more than I ever dreamed about coils, dwell time, spark duration and timing advance tables. I hope to be running for next summer.

 

Good to see more Microsquirt conversions. Mine has turned into a long term saga

What climate is this build in?

Unless its a cold climate, it may pay to consider a decent size oil cooler.

Looking forward to updates.

 

If anyones good with megatune if you could make a basemap for me to look at that would be great i kinda want to see if the map i made is a good starting point. i live in iowa so are weather is all kinda of temps.

Desinger_Mike i had to hog my intake boots out so i could get them to fit i was wondering what they came off of thanks for clearning that up. Not sure on the fuel pump draw but i dont think its much being that it came off a 4-wheeler its regulated at 43psi with no return.

Its been cold here so i dont like to work lol plus im waiting on fuel pump and trigger wheel to come in then ill be cranking out the updates.

 

Gennro did an EFI conversion on a XJ700 airhead with a microsquirt

http://www.xjbikes.com/Forums/viewtopic ... 0+efi.html

It's undoubtedly a bit different but should provide you with a starting point anyway.

There is also a good microsquirt forum with helpful members there too and specific success stories.

 

I give up on the microsqurit forums they dont ever help you with your problems just cause there dumb questions but anyways ive tried to get ahold of gennro but cant thats what started my whole build was his post.

 

Another thing the Turbo has, are cams with no "overlap".
The XJ's have many degrees of overlap - you will be blowing alot of your charge right out the exhaust- - time to shop E-Bay for a pair of cams.

 

That reminds me, Isaacson...you mentioned that you have a 650 turbo oil pump. I've never opened my bottom end but it looks like the turbo has the scavange pump "built on"(added to) to a stock pump, basically adding a pump chamber with an additional rotor to circulate the turbo's oil.

It will be interesting to see if you can simply swap out the stock 650's pump with the turbo's pump. Also, you will need the additional plumbing to actually be able to circulate this new oil system through the filter. Clean oil is must for a turbo shaft that spins up to 210,000 rpm and rides in a oil bearing.

This should be a cool build, won't be easy but will be cool

jeff

 

Is there any reason why you have chosen a 3 bar map sensor instead of a 2 bar unit?

Unless you intend to go past 14psi boost, a 2 bar sensor will have more sensitivity due to the larger usable range.

 

(Note to self...darkfibre knows his stuff re: EFI)

 

Chose the 3 bar map so I don't have to rescale the map when I want to up boost. For the oil pump swap you need the turbo oil pan and the pump but you do have to swap the drive gears so far it works great sucks the oil out of the turbo don't have to worry about oil backing up and taking out the seals.

 

Hey darkfibre are you any good at tunerstudio ? Could you help me get the right setting setup for my bike ? I'm kinda stuck on the trigger wheel setting like how many to skip and where to set the 36-1 wheel up to tdc ? Any idea every thing I've read says the first tooth after the missing one is tdc but the you count 8 teeth then there's where the vr sensor goes. But that doesn't make since to me at all.

 

I don't have my XJ700 anymore and parted it out. Bought a 2001 Yamaha V-max so you can stop messaging me everywhere. Thanks!

 

I will be setting up my 36-1 set up over the Christmas - new year break.

TDC is not a trigger wheel setting, it is a physical engine position.

Once you have installed the trigger wheel you then need to do 2 separate things.

Program the Microsquirt to use a 36-1 trigger wheel

and

Program the Microsquirt for base timing point by tooth count and fine tune with offset.


How many teeth you count past the missing tooth totally depends on the relationship between your trigger wheel and the actual engine position.

Every custom trigger wheel set up will have different settings.

 

all i wanted was some help man not trying to be an ass sorry

 

so it doesnt really matter where you put the trigger wheel on at the missing tooth doesnt need to be set anywhere?? thanks again

 

I will post up my set up with reasoning and pics soon.

 

thanks man i need the help lol im trying to fire mine up in the next month or so i have everything i need to start it but need some guidance

 

Don't sweat it Isaacson, there was plenty of talent here before, and even more now. The guys will get you hooked up.

jeff

 

hey guys ive ment to update everyone on this bike but work has been crazy. the bike has been running for about 2 months now and running strong on 9psi so far waiting to get it on the dyno to up the boost going for 120hp on this bike/engine setup. heres some pics ill get some up tommrow.

darkfibre if you could pm me ive got some questions for you.

 

Bitchin dude, hows it ride?

 

its pretty fast but still not fast enough

 

Cool bean's.
Al

 

Is anything ever fast enough?

 

do you have some videos of it running?

 

how is the spool with that large of turbo.
when does boost hit in 1st, and 2nd gear?