:corn

 

Hope it all goes together easy for ya mate. :thumbup
I'm in for the build up. :fact

 

Subscribed... This should be awesome...

 

should be pretty sweet when you get it done. cant wait for build pics. seems like it would be a one day/ one case install

 

Is this a DynoMite (UK) supercharger kit? I know they offered one awhile back along with modified R1 mids to fit the side the superchager bits were on :corn

 

http://www.rotrexsuperchargers.co.uk/Rotrex/pages/products/bikes/yamahar1/prod_yamahar1.html

 

looking forward to results

 

subscribed. did you do a dyno pull on the bike to get base numbers to see what the kit really adds?

 

Not quite starded



Yep. the bike was never a ball buster. last mapping was 159 without ram air.
the kit is from TTS Performance
http://www.rotrexsuperchargers.co.uk/Rotrex/pages/products/bikes/yamahar1/prod_yamahar1.html (spot on redgeko)
The inlet and airfilter configuration, has been modified to fit pointing backwards next to the head and above the pulley and looks MUCH neater than where it was origionally jammed infront of the head in their pictures.
It's pretty well bolt on, though i will have to modify the fuel pump, compression ratio, fairing, ECU and Fuel map (off the top of my head)

I'm picking up 2 new standard head gaskets tomorrow (not included in the kit) which will drop the compression enough to still use pump fuel (minimum 98), and I will alter the regulator in the fuel pump to allow the pump to run up to 4.5bar (standard is 3bar).

It's not quite a 1 day job for me, im working on a video for the build and plan to check clearences and tollerences whilst im rootin' around in there.

here's an unremarkable pic of getting things ready for the build.

 

Subed! This is gonna be sweet!

 

video? great to hear

 

End of Day 1

SO....
I have the head gaskets, and have started tearing the bike to peices.
On day 1, I have learned the following:

1. Removing the fuel pump is as easy as removing a ship from inside a bottle.
2. I was reminded that foam backed heat shield doesnt like fuel
3. This kit is far from bolt on, but that adds to the fun!
4. the exhaust and engine block will need to be modified
5. my hopes of doing this while still mounted in the frame are proposterous!!

still there is light at the end of the tunnel

 

Do they advertise this is as a bolt on system?

 

:corn

 

Just out of curiosity I don't see anything changed with the clutches in this kit?

How is the adding fueling corrected? Larger injectors?

I have had a wee bit of experience with the topic is all... Good luck can't wait to see it completed.

 

not advertised as a bolt on, more along the lines of a kit with everything needed. I assumed it would pretty much be whack it on and 'make her take it!' but its going on regardless.

by placing the a blanking rivet in the fuel pump regulator
this will aparrently cause the pump to run at 4.5 bar instead of 3 bar. the rest is done with mapping through stock injectors with a PCIII in my case. i dont expext to need to do anything to the clutch, since its not a massive power addition

 

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

 

on day 2



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.

 

:corn

 

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.:corn

 

still on day 2



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!

 

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

 

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.

 

End of day 2

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)

 

Day 3

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.

 

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

 

After day 4

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!

 

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

 

Whaa nice knobhead

Sent from

 

day 6

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