Vivian - Banner's streetfighter experiment.

Post by **creedxup** » Wed Jan 29, 2014 10:25 am

banner001 wrote:
creedxup wrote:The plastic plate that the coils attach to is also designed to deflect hot air away from the air box to keep the inlet charge as cool as possible.
aye, but the bike will eventually run ram-air, so it will only be pulling in cool air from the front of the bike, ill also make the airbox larger so any heating will be dissipated over a larger area. its how my race bike runs and ive had no problems so far. i might try to keep the plate, but it will be a modified one, ill have to see once i finalize the front wiring loom.

Cool, sounds like you've got it all in hand.

banner001 · Post by **banner001** » Wed Jan 29, 2014 11:56 am

im going to see if someone like bdk racing can make me a custom airbox - they make zxr400 ones - if not ill modify the existing airbox to get a rough idea of what can be done (will need the radiator and oil coolers repositioning slightly lower, and slightly further back), dont want to have to "letterbox" my radiator if i can help it, i need to check the height the coolant gets to in the engine as there is a physical limit to how low you can drop the radiator.

and if all that fails, ill see if its possible to make a semi-effective ram air using the non-functional frame cutouts as my bike is fightered and doesnt use them...i might have to make a metal insert to help direct the air in...

and if that doesnt work...ill stick with standard, keeping my options open

banner001 · Post by **banner001** » Sun Feb 02, 2014 11:45 pm

headlight clamps are here, theres no mounting point for the indicators (yet), so its washers and friction holding them on at the moment...but they look good, good enough for the next year at least (before the radial front end gets fitted)

ive knocked up a bracket for the horn (will NOT be the final solution) so that turns with the forks as well, now im just waiting on acewell to deliver me my clocks, then i can wire in the electronic speedo pickup, new water temp sender, and air temperature sender, and i can make my front loom!

here's the view all the people in front will get (minus clocks)

Post by **creedxup** » Mon Feb 03, 2014 12:10 pm

Looks good from the front.

The height of the coolant in the head is approx 5mm below the joint between the head and the cam case.

Gord · Post by **Gord** » Mon Feb 10, 2014 5:35 pm

I changed my YZF 750 choke lever for a Thundercat choke lever, it's all part of the left hand switch gear. It makes it look a lot neater than the standard set up.

banner001 · Post by **banner001** » Mon Feb 24, 2014 3:19 pm

cant find any decent thundercat switchgears, but there is a decent looking thunderace one (also with choke lever) on ebay, ive stuck a bid on it, would be nice to bring the choke up onto the handlebar.

im currently buying a proper wire striper, crimper, and a load of wiring from here
http://www.vehicle-wiring-products.eu/V ... mepage.php

ive emailed acewell to see when the clocks will be here...front end is starting to come together

ill be fitting a thunderace or R1 throttle at some point too as i think it looks smarter than the current one.

ive been pulling out wires (ive also noted that the "UK" wiring in the service manual is not what my bike has, mine is more like the wiring in the haynes manual), so i have an oil light relay in there.

so far ive removed the 2 unnecessary (green/white and yellow/red) wires from the original indicator relay and ive fitted my new LED relay (tested with all 4 indicators and looks fine). im currently in the process of removing the clutch and sidestand lockout switches fully:-

i think ive got it right, i need to connect the black/yellow and blue/yellow wires from the relay to ground (black wire), and i need to connect the blue/yellow wire from the CDi to ground as well...ill test it tonight, if its ok im going to shorten the wires so they are as short and compact as possible.

ive also wired the reserve switch permanently on and removed the wires for the resistor and the fuel sender as these are now redundant (and ill be fitting a proper fuel gauge).

then if thats ok ill look at removing the oil light relay (it does nothing as far as i can tell) and that should be ok for the moment. i dont think there will be any more wires to remove.

banner001 · Post by **banner001** » Fri Mar 07, 2014 4:14 pm

found this for the fuel tank...might be able to get away with this and a rubber/cork seal for the underside of the fuel tank...ill measure it tonight.

https://www.merlinmotorsport.co.uk/p/vd ... 0-264-1241

banner001 · Post by **banner001** » Sun Mar 09, 2014 7:03 pm

been tinkering...

ive "dry" tested it, and im pretty sure if i get stick coils fitted, i should be able to relocate almost all the electrics to under the front. ill cut a replacement bit of plastic and fit "fingers" to it to allow me to hold the various components in place.

ill make it longer so it fits over the engine completely and keeps the heat out, and ill probably shield the carbs with some reflective matting to keep the heat down...i might get hold of a temperature datalogger and test it on my zxr to see how much heat resides under the airbox...i think it will be fine, it might get up into the 40C's or 50C's...but it will be fine.

the pink/green sponge is the same size as the fusebox so i could gauge it.

banner001 · Post by **banner001** » Mon Mar 17, 2014 9:18 am

my

clocks

arrive

tomorrow

, and the rest of my wiring/fusebox/crimp connectors/battery crimper etc will be middle/end of next week...i know what ill be doing for the next month

banner001 · Post by **banner001** » Tue Mar 18, 2014 8:08 pm

now i have a mass of wires:

and a sweet clock...

now to get on with buying the last of the wiring and start the full re-wire

banner001 · Post by **banner001** » Fri Mar 21, 2014 10:12 pm

The rewire is underway

banner001 · Post by **banner001** » Sat Mar 22, 2014 9:19 pm

been cutting the wires for all the relays/cdi/fusebox etc, and insulating as necessary. doing it this way i can ensure that the only "old" bits are the physical boxes themselfs. ive manages to make a plastic template from the old temperature shield (what the coils attach to) and ive worked out where to attach my boxes, the airbox still fits, and there should be space inbetween the oil relay and CDi, and inbetween the CDi and relay junction box to fit most of my bikes wiring, or it will go down the edge of the frame and oil relay/junction box...ill be fitting stick coils and should have loads of room.

im making up my lengths of wire fairly precisely (within 2mm) so that i get a calculated bend (look at the CDi for instance) and my wires are not gonna be under tension/compression - should increase their life.

im doing the bits that dont require me to do much work first, so things like the pickup coil, spark plugs, fuel pump etc, i need to get my clocks onto a bit of a homemade bracket next (ill measure it and CAD draw it tomorrow) so i can work out how to wire them up into my new loom, ive semi-sorted out where i want my wires to "spur" from, its just a case of packing them all in now

i should have enough room, im not able to measure it exactly, but it looks like there should be plenty of space, it should also make removing the loom easier as it will be very thin where it snakes under the carbs and inbetween the seat and the frame/engine.

more tomorrow

Post by **nuggitt** » Sun Mar 23, 2014 8:39 am

Very artistic John.

banner001 · Post by **banner001** » Sun Mar 23, 2014 8:24 pm

did a quick cad mockup of a possible clock mount:

looks ok when its mounted with the clock, but it will need modifying, and its mounted too far from the yokes at the moment:

from the front:

modified some of the mounting points a bit and moved the fusebox, checked with the airbox it all still fits...so all good so far

this was earlier in the day, ive been wiring like a demon today, ill be off out again in a bit, want to wire a few more connectors, im almost at the point where i need to start wiring the lights and indicator bulbs...that kind of thing, so im making headway.

no guarantees that it will all be good yet, but im pretty hopeful

banner001 · Post by **banner001** » Mon Mar 24, 2014 12:55 pm

situation as of last night, gonna start wiring in the switches and lights soon, last will be the clock power/tachometer/fuel sender/battery and the exup servo (needs extending to the back of the bike):