HOW TO: 07-08 R1 Install Rotrex Supercharger

[Spyrious]

Yes.He is one of the few gurus of the tl1000.He now has overbored it to 1200cc,but that off topic.

[cyclepsycho7]

can't wait to see the finished product.

[Doppler]

I'd hazard a guess that this would be one of the most watched threads on the forum.

Awesome. We can't wait!

[Raven1Actual]

In for the thrill.

[forestR1]

Although ive been told that the gasket has held up on the origional build bike (mine is only the 2nd kit to be produced) I am still giong to countersink a coverplate into the back of the bracket to mate with the timing cover gasket to be sure.

OOPS-- I had to remove the master pully to work on the bracket, the retaining compound wouldnt break and so i trashed the iol seal and bearing in the bracket before i realised that i was an idiot. thankfully the bearing and oil seal were off the shelf componants and cost me 9 whole dollars to replace.

I dont have the means to weld the aluminium bracket so i will have to wait till the ally fab shop re-opens. or maybe ill just use "Kneed-it" and do it today. sounds legitimate.

In Picture: the grey is the where the bracket mates with the open timing housing, the hole is where the tensioner mounts (on the reverse side). how this would have ever lasted i dont know!

[T.C.]

Do it once, and do it right. I'd wait for the fab shops to re-open.
Not sure what it's like in NSW, but they start opening here in Vic the second week of Jan.

[forestR1]

Originally Posted by T.C.

Do it once, and do it right. I'd wait for the fab shops to re-open.

Very sound advice T.C always best to do things right!
So anyway... after I stuffed some Kneed-It in the hole and scraped it flat and tapped out some other holes the charger is now mounted in all its glory!

I used an oil wrench to put tension on the tensioner while i fixed it in place, and since i Stuffed the bearings last week and had to replace them i got a pic this time of how to get the spiggot into the double lip oil seal (you cant just push it in because the lip is smaller and faces outwards), so feeler gauges placed between the spiggot and oil seal all the way around like an apature make it pucker up and you can pop the shaft in.

I have fluids back in the bike (apart from the Supercharger) and am working on the fairing and oil routing for the SC still.

Hopefully will have some actual interesting stuff for you soon.
lets face it the only thing everybody wants is to see is this thing flip!

[Medevack1]

Nice work !!!!! im sub too......

[toysareforboys]

In for dyno charts (and videos).

-Jamie M.
(P.S. did you see I said videos? Good ).

[forestR1]

A mate came round today to help so things actually got done!

Today:

1. Most of the fairing is done with the help of an angle grinder, a dremel and some photos for reference. after about 20 go's we got bored and started on the oil routing.


2. Got most of the oil routing done and have it pretty much figured out but pulled up about 2Mtr short of line and the one way valve supplied is too small to fit properly. Sort that out tomorrow!

All that is left after that is priming the oil circut and tuning. Im trying to get hold of a fuel map to use as a base, but the bike was runing spasticly rich beforehand so that may be enough for a gentle break in if i turn up fuel a little more.

and then... Wheelies!
and then... crashies!
and yes... Videos!

[forestR1]

THE BIKE RUNS!!!

Had the boys around for a starting party today.
here's how it went down:

1. finished the oil circuit and managed to make everything fit (oil lines and powercommander were tight

2. Primed the oil circuit. By the book, you are meant to use compressed air to push the fluid through, that didn't want to make it passed the one way valve so i pupmed it through the lines with a measuring syringe.
- then we tightened up the forgotten banjos on the oil cooler and cleaned up the mess

3. Fuel tank on, battery connected, blow off valve DISCONNECTED, camera rolling, ignition on... then... *59*
Had a quick look and 59 is TPS (throttle position sensor). that looked to be connected, so bugger it!

4. Hit the starter, engine turns over, belt winds up! but no firing. ...TPS
I looked further into it, turns out i was looking at the throttle blade sensor not the TPS which i can see is unplugged and burried by the plenum chamber.. So off comes the plenum chamber (painfully) and the plug is reconnected. ignition on... ALL GOOD!

5. Camera back on, starter button, engine turns over and fires into life. with a subttle new whistle! The reason the blow off valve was disconnected (ie: removed leaving the port open) was to test the bike all rigged up without boost. The engine would take the air it needed and the rest let out the empty BOV hole. This was a good idea.
A few gentle blips of the throttle and the other side of the bike was generously sprayed with bright blue traction fluid (the supercharger oil)spat out of the BOV port killswitch!

roughly 100ml of oil had leaked form the drive side of the SC where it belongs and pooled in the compressor side and was blasted up the air pipe to the BOV outlet and air box. messy.

We cleaned up a bit and disconnected the air pipe from the supercharger so that when operating, the air would blow straight out and we could see what was going on. it wasnt leaking now, so we fired it up again and... nothing... all fine. The only thing we could think of is that it was forced through the seal during priming. Ill see what's what in the morning. hopefully all dry!

Ill get some more pictures and video up soon
Cheers

[TheBFA]

Originally Posted by forestR1

Although ive been told that the gasket has held up on the origional build bike (mine is only the 2nd kit to be produced) I am still giong to countersink a coverplate into the back of the bracket to mate with the timing cover gasket to be sure.

OOPS-- I had to remove the master pully to work on the bracket, the retaining compound wouldnt break and so i trashed the iol seal and bearing in the bracket before i realised that i was an idiot. thankfully the bearing and oil seal were off the shelf componants and cost me 9 whole dollars to replace.

I dont have the means to weld the aluminium bracket so i will have to wait till the ally fab shop re-opens. or maybe ill just use "Kneed-it" and do it today. sounds legitimate.

In Picture: the grey is the where the bracket mates with the open timing housing, the hole is where the tensioner mounts (on the reverse side). how this would have ever lasted i dont know!

I'm in Sydney Eastern subs and can weld aluminum if you want me to have a go. I could even see about some exhaust modification for you if you want, if you are in the area.

[forestR1]

Originally Posted by TheBFA

I'm in Sydney Eastern subs and can weld aluminum if you want me to have a go. I could even see about some exhaust modification for you if you want, if you are in the area.

Cheers BFA. I'm up north and the bracket is sorted (i hope). thanks though.

[rexmitchell]

subscribed

[benji0383]

Any Updates??

[2 Raven Rider]

[forestR1]

Put the bike on the Dyno last week. left there very dissapointed.
The final result was around 164 HP at the wheel!

There were big issues tuning the 20% throttle range. The fuel map is basicly turned on it's head, adding 20 to 60% fuel everywhere elso, to minus 20 to 60% around the 20% throttle opening. this was the only result we could come up with on the dyno.

The ride home (the first road ride under boost) was bad, power was on and off like a switch, so into fault finding.

1. I calibrated the BOV, increasing minimum pressure thinking that maybe it was opening on the dyno stuffing up the fuel map.
-minor improvement

2. I adjusted the fuel map. I dont have a Dyno in my pocket so i replaced the 20% throttle range fuel changes with the averages of the adjacent cells to just smooth the map out (if anyone has powercommander software you'll know what i mean). This was never intended to be perfect, but in the ballpark.
-Bloody lethal! at low - medium throttle the bike would start to speed up the get to certain rev ranges and turn into a jackhammer as if spark was being cut and comming back on 5 times a second!

today i downloaded some screen capture software pluged the laptop into the PCIII, threw the laptop in a bag and went for a ride. Im still trying to analyse the results.
Im also having big problems with the oil reservour ill explain in the next post

Sorry about the wait, i've been holding out for some good news for you all.

[swerwer]

Good luck man.. sure you'll get it figured out somehow....wouldn't the manufacturers be able to assist? she'll be a beastie once sorted though

[OptimoPrime]

yul get itgoing man.

when i was on dyno we were having a problem where even if we added 100% more fuel it would stil only get to 13s. we replaced the fuel pump and everything immediately went up into the 18s. we redid the tune and it came out great.

maybe check your plugs/coils/fuel pump?? idk if this helps but its only experience on dyno i've ever had

[cyclepsycho7]

Good luck with the finishing touches!!! Subed!!!!