HOW TO: 07-08 R1 Install Rotrex Supercharger

[snoman48]

[forestR1]

Originally Posted by malikowy

what clutch you have already installed? i would install EBC Kevlar clutch set just in case something might or not happen

Nup sticking with a bog stock clutch for now, if it slips ill throw in tighter springs and kevlar friction plates. i prefer the stock feel, & find beefed up clutches tend to shudder.

I have managed to squeeze the SC on without the exhaust and an oil duct, the solid oil ilne is at the engineers with a rough sketch for modification and i have cut off a mount on the engine which i assume is just to hold the engine in a workshop stand

to make things a little harder, the mounting bracket wasn't drilled out deep enough for the locator pins in the timing cover that the bracket replaces, so ill drill those out myself.

[NoxImus]

Originally Posted by forestR1

I AM SUPERCHARGING MY 2008 YZF R1.

Because I coun't find much info anywhere, i will do my best to give you as much info as i can as I carry out this project.

INTRODUCTION:

Method: Kit ! (purchased and arrived!) self fitting
Cost: $5000 max (i hope. looks good so far)
Time: Kit build from manufacturer + 1 week (expected)
Expectations: up to 210 WHP - aiming for 200. expecting: 195-200 (on minimum 98 Octain fuel.

Ill have more information / pictures up soon!!!

Wonder how far off this would be from fitting a 2012... I have no idea what the duct work looks like on the pre 09's.

[forestR1]

Originally Posted by NoxImus

Wonder how far off this would be from fitting a 2012... I have no idea what the duct work looks like on the pre 09's.

this particular kit wouldnt stand a chance of fitting but there's no reason it couldnt be done. the 09 was re-designed from the ground up. I have a mate's big bang in the shed and there's nothing in common.

day 2 cont
We've lowered the engine by pivoting it on the lower rear mount and using the chain and chain adjusters to set the angle this works great, but i cant for the life of me remove the throttle bodies, there is one bolt ill need to make a tool to get to.

hope to get the head off tomorrow, the missus is heading off for a couple of days so i wont get lynched for working in the head in the kitchen!

[djt77]

great work so far, got me looking for a crashed one to build up

[swerwer]

Looking good. Good luck with the build. "the missus is heading off for a couple of days so i wont get lynched for working in the head in the kitchen!" that's why i built my old kitchen into the garage. can't wait to see the results.

[forestR1]

The throttle bodies came off, there was a hose clamp that was facing the wrong way, so i made a tool to get at it.... ....not!
RIP TEAR BUST! Ill fix that up later! and I have the cam cover off now, so i think the head is very achievable tomorrow. I plan to check valve clearences whilst im in there so it may not be back together tomorrow, im not a mechanic so im a little slow (mechanics are much much slower, according to their invioces hehe)

[forestR1]

The head's off, I checked the valve clearances and most of them are ok but I’ll have to get some different sizes tomorrow. Not having any luck with the oil line yet, that and the exhaust will be the painful bits i think.
I gave the upper deck a little clean up, acetone cleans the old gasket goo straight off. Everything looks all right in there, the cylinders still have a nice crosshatching to them.

tomorrow - correct valve clearances, re-install the head with 2x head gaskets, Keep trying to figure out oil pipe mod and exhaust (i have beautiful Graves titanium headers and i'd prefer not to trash them) and if i can get the engine back in I’ll start routing air ducts and oil circuit.

The Rotrex have pretty a pretty handy set up on their S/C, there is no need for a scavenger pump and it runs its own closed off oil circuit which the S/C also pumps for its self. nifty.

[m6agent]

Very nice project, keep going like this with photo and video,...... very interesting to read your posts .....

[forestR1]

Head gaskets are in now the compression is low enough to use pump fuel.
Vlavle clearances are sorted back to well within spec (a few were a bit out).

I followed the workshop manual (mostly) when i pulled the cams out, also i marked the cam chain and timing gears and input. when i put it back together nothing was where the manual said it should have been. i would be comfortable with that only my clear marking are not so clear anymore and its not worh the risk to me if i get something wrong, so im going to seek council today.

No solutions for the oil pipe or exhaust yet.

The plenum chamber routes through a shelf just behind the stearing head where the air filter sat, the regulator/rectifier also lives there because the ram air heading to the airbox keeps it cool. The new system will render the ram air ducts obsolete since the air will now enter through a pod filter near the supercharger and duct straight up into the plenum chamber. i can still fit the reg/rec in the cavity and the with the shelf gone there should be plenty of ventilation for the reg/rec

Progress today will depend on getting the valve timing right.
If anyone knows how to figure out if a pot is on compression stroke or power stroke WITHOUT relying on the cam lobes, I'm all ears!

[forestR1]

Originally Posted by forestR1

If anyone knows how to figure out if a pot is on compression stroke or power stroke WITHOUT relying on the cam lobes, I'm all ears!

Never mind... I wanted to know this so the spark wasnt on the wrong stroke. I just learned that these engines run a wasted spark (spark fires on every stroke) so it doesnt matter.

and here a picture of how the supercharger kind of looks like a wang. cool

[swerwer]

Whaa nice knobhead

Sent from

[forestR1]

I've sorted the cam timing, turns out i mis interperated the manual. the engine is back up and bolted in. Ive been told by TTS that the oil pipe i've been having problems with is just a drain pipe and can be sealed without consiquence, I tend to think yamaha would have put it there for a reason so im still going to modify it but atleast im no longer worried about modifications upsetting any flow.
Great news, with minimal messing around i hae also managed to install my Graves header pipes WITHOUT MODIFICATION! this was gonna pe a pain so im pleanty happy about that.
The plenum chamber is now attached to the throttle bodies, I still have to find a way to mount the regulator-rectifier, but that might yet just be zip tied to the plenum inlet pipe. Go team!

Still to go: radiator, S/C oil lines, mini Pod filter for the now detatched crank case breather hose, fairing.... bla bla bla. wooooh

[forestR1]

i got lazy today, little bit of cable routing, putting things back together and smelling of stale burbon sweat.

[OptimoPrime]

keep it up bro, i'm loving the build

[forestR1]

wow! time has gotten away
have been tied up for a few days.

Had the oil line modified by the local engineers, $260 later it still didn't fit.
One mate with a welder, a few hours, and a few beers later, looks like we have a winner!
now progress can continue.

because of the delay, i highly doubt ill be able to get the bike on the dyno over christmas which is a bugger, i'll try, but i think it will be after new years cause they'll probably be closed.
I still have plenty left to do, the fairing that was on the bike (Norry Haga - Santander 2008 WSBK) is just some cheap junk from hong kong that i threw on. I have had cheap fairing in the past and it was absolute rubbish. my welding mate got some not long ago and it was perfect, so i tried again. NOPE!!! shit. so the origional 2008 white/red will go back on i think (after i chop bits off it!).

Ill get some more photos up soon when there's something worth looking at.
cheers!

[Fonzi03]

ohhh man you got me hooked, love superchargers!!!! any chance you guys know of one that would fit an 03?

[forestR1]

Originally Posted by Fonzi03

ohhh man you got me hooked, love superchargers!!!! any chance you guys know of one that would fit an 03?

Mine came from rotrex.co.uk it was the only model R1 kit that they had already built, most of the kit was off the shelf and they made the S/C mounting bracket, oil resivour, plenum chamber air duct and brackets for the oil cooler and the S/C inlet pipe.

apart from the S/C bracket and plenum base which were CNC machined everything was made fairly simple with aluminium sheet and tube. there are enen more simple designs out there where the plenum chamber is just made out of a peices of tube. no reason it couldnt be done, but i dont know if there's a kit out there already that you can get.

[toysareforboys]

In for dyno chart on pump gas

-Jamie M.

[Hung]

Good project...plz keep it update