Suzuki DR800 fuel injection project - Page 2

LukasM · 12-22-2008, 07:14 AM

If somebody wanted to do the same thing on a DR650 they could use the head off a European XF650 Freewind as it has dual inlets as well.

Just saying... Would be nice if somebody was the test rabbit so I can just copy the final working result.

ambraa · 01-07-2009, 03:08 PM

I finally got time to modify the TB's. It was quite simple, removed the hoses, fuel rail ++ and the two long bolts through the four separate TB's. I mounted the outer ones together with shorter bolts, cut and welded the fuel rail and then they look like this: PICTURES

Also added some pictures of the fuel pump.

Hope to connect the pump and TB to test for leaks during the weekend.

I have some trouble getting a correct RPM reading from the VR sensor on the bike, but got a few tips today so I hope it will be sorted pretty soon.

azcagiva · 01-07-2009, 03:35 PM

I was considering doing this on my elefant. I read something about a guy that used a microsquirt to replace the computer on his 1150gs. He had it setup so he could change his fuel tables and such with his palm pilot.

Some of the DIY fuel injection systems I have looked into(For a hotrod project) have a self learn function. You put in some generic fuel tables and it will correct them when in the tune setting. I ended up getting a link 4 system but have had to put it on the back burner untill I get some more time.

Very cool, please keep us updated.

-John

ambraa · 01-15-2009, 11:54 PM

Last night I tested the sensors and fixed the rpm signal problem. The RPM on the MS was twice that of the tacho on the bike. Changing the settings in Tunerstudio to 2 cylinders with simultaneous 1 squirt solved it.

A couple of PICTURES.

mousitsas · 01-16-2009, 01:26 AM

thank you ambraa for keeping us posted with your progress.
I recently came across ths product:

www.afrtuner.com

and thought you might be interested.

drhach · 01-16-2009, 06:51 AM

More Pictures Please.

Letsgo21 · 01-17-2009, 04:00 PM

Great project, looking forward to more results and pics

ambraa · 01-27-2009, 02:10 PM

Good progress this weekend. Got all the sensors mounted on the bike and it all seem to be working

Very little space left, but should be enough for the airfilters and fuel lines. Seems like I have to wait another week for the intakes and the oil-temp adapter...too bad since the rest is more or less ready for a test-start.

PICTURES (taken with mobile phone so not the best quality)

mousitsas: The Motty tuner is interesting, nice product. But I think it might be more like a Powercommander, for tuning a bike with stock fuelinjection. I don't think it can control the fuelpump or ignition as the Microsquirt can (correct me if I'm wrong).

Thank you all for the comments and interest in the project. It gives good motivation to get things done

JSL · 01-28-2009, 07:44 AM

LukasM · 01-28-2009, 07:53 AM

Glad you are making progress with this! I bet the cold winters up North help quite a bit in getting things done.

I'll start looking for a cheap twin inlet Freewind head for my 650 then!

ambraa · 01-28-2009, 08:52 AM

Thanks!

Yes, it's usualy the choice of go skiing or stay home in the workshop

Until now there has not been enough snow here in the eastern parts so I've spent a lot more time with the bike than I had planned.

There has been some head-scratching but owerall I'm a bit surprised that the Microsquirt system has been almost plug and play so far. I'm sure that may change when the tuning begins

Also the info in the megamanual and the mega/microsquirt forum has been very good and helpful.

Just start looking, I think the Freewind head + injection would be a very cool mod to the 650. Do you know if the valve sizes are different in the Freewind head?

ambraa · 02-15-2009, 10:58 PM

Got the intakes and the oiltemp-adapter last week. After a few "adjustments" everything seems to be ok. I've also pressure tested the fuelsystem and it worked fine without any leaks.

The remaining things to do before trying to start the bike is welding on a fitting for the return fuel hose and going through the settings in Tunerstudio one more time. Should be plenty of time for that next weekend

I forgot the camera so no pictures this time, will add some later.

JSL · 02-18-2009, 09:40 AM

mousitsas · 02-18-2009, 10:46 AM

Ambraa,
What AFR are you going to target for your tuning?

ambraa · 02-20-2009, 05:35 AM

Hi mousitsas,
I will use the recommended values from the megamanual. Somwhere between 12.5 and 13 for high load and 15.5-16 for cruising. I'm hoping that the vacuum signal would be ok for a alpha-n/MAP blend. I believe that would be easier and quicker to tune with the butt-dyno

12-22-2008, 07:14 AM	#16
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,913	If somebody wanted to do the same thing on a DR650 they could use the head off a European XF650 Freewind as it has dual inlets as well. Just saying... Would be nice if somebody was the test rabbit so I can just copy the final working result. __________________ Proud member of the HUSABERG ADVENTURE TEAM! '12 Husaberg FE570, 09 KTM XC-F/ 450 RFS hybrid, 07 KTM 450 SMR, 08+09 BMW F650GS twins/F800GS conversion, 03+05 YZF-R6

01-07-2009, 03:08 PM	#17
ambraa ^OP Adventurer Joined: Aug 2007 Location: Oslo, Norway Oddometer: 70	Update I finally got time to modify the TB's. It was quite simple, removed the hoses, fuel rail ++ and the two long bolts through the four separate TB's. I mounted the outer ones together with shorter bolts, cut and welded the fuel rail and then they look like this: PICTURES Also added some pictures of the fuel pump. Hope to connect the pump and TB to test for leaks during the weekend. I have some trouble getting a correct RPM reading from the VR sensor on the bike, but got a few tips today so I hope it will be sorted pretty soon. ambraa screwed with this post 01-16-2009 at 10:17 AM

01-07-2009, 03:35 PM	#18
azcagiva new orange flavor Joined: Apr 2007 Location: Camp Verde, AZ Oddometer: 1,058	I was considering doing this on my elefant. I read something about a guy that used a microsquirt to replace the computer on his 1150gs. He had it setup so he could change his fuel tables and such with his palm pilot. Some of the DIY fuel injection systems I have looked into(For a hotrod project) have a self learn function. You put in some generic fuel tables and it will correct them when in the tune setting. I ended up getting a link 4 system but have had to put it on the back burner untill I get some more time. Very cool, please keep us updated. -John __________________ An Elefant never forgets. 2012 Baja 1000 www.Raceforthewounded.com Help us race the 1000, and double the value of your KLR by buying a t- shirt

01-15-2009, 11:54 PM	#19
ambraa ^OP Adventurer Joined: Aug 2007 Location: Oslo, Norway Oddometer: 70	Signals and sensors working Last night I tested the sensors and fixed the rpm signal problem. The RPM on the MS was twice that of the tacho on the bike. Changing the settings in Tunerstudio to 2 cylinders with simultaneous 1 squirt solved it. A couple of PICTURES. ambraa screwed with this post 01-16-2009 at 10:16 AM

01-16-2009, 06:51 AM	#21
drhach gorillamanufacturing.com Joined: Nov 2006 Location: Waukegan Oddometer: 1,880	More Pictures Please. __________________ 1976 R90/6 1972 XLCH 2010 Triumph Thunderbird SE

01-16-2009, 01:26 AM	#20
mousitsas Beastly Adventurer Joined: Oct 2008 Location: Athens, Greece Oddometer: 2,144	thank you ambraa for keeping us posted with your progress. I recently came across ths product: www.afrtuner.com and thought you might be interested.

01-17-2009, 04:00 PM	#22
Letsgo21 Gnarly Adventurer Joined: Aug 2007 Location: Hannut,Belgium Oddometer: 147	Great project, looking forward to more results and pics __________________ The blues is the soundtrack to reality

01-27-2009, 02:10 PM	#23
ambraa ^OP Adventurer Joined: Aug 2007 Location: Oslo, Norway Oddometer: 70	Sensors mounted on the bike Good progress this weekend. Got all the sensors mounted on the bike and it all seem to be working Very little space left, but should be enough for the airfilters and fuel lines. Seems like I have to wait another week for the intakes and the oil-temp adapter...too bad since the rest is more or less ready for a test-start. PICTURES (taken with mobile phone so not the best quality) mousitsas: The Motty tuner is interesting, nice product. But I think it might be more like a Powercommander, for tuning a bike with stock fuelinjection. I don't think it can control the fuelpump or ignition as the Microsquirt can (correct me if I'm wrong). Thank you all for the comments and interest in the project. It gives good motivation to get things done

01-28-2009, 07:44 AM	#24
JSL Adventurer Joined: Nov 2005 Location: Finland Oddometer: 44

01-28-2009, 07:53 AM	#25
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,913	Glad you are making progress with this! I bet the cold winters up North help quite a bit in getting things done. I'll start looking for a cheap twin inlet Freewind head for my 650 then! __________________ Proud member of the HUSABERG ADVENTURE TEAM! '12 Husaberg FE570, 09 KTM XC-F/ 450 RFS hybrid, 07 KTM 450 SMR, 08+09 BMW F650GS twins/F800GS conversion, 03+05 YZF-R6

01-28-2009, 08:52 AM	#26
ambraa ^OP Adventurer Joined: Aug 2007 Location: Oslo, Norway Oddometer: 70	Thanks! Yes, it's usualy the choice of go skiing or stay home in the workshop Until now there has not been enough snow here in the eastern parts so I've spent a lot more time with the bike than I had planned. There has been some head-scratching but owerall I'm a bit surprised that the Microsquirt system has been almost plug and play so far. I'm sure that may change when the tuning begins Also the info in the megamanual and the mega/microsquirt forum has been very good and helpful. Just start looking, I think the Freewind head + injection would be a very cool mod to the 650. Do you know if the valve sizes are different in the Freewind head?

02-15-2009, 10:58 PM	#27
ambraa ^OP Adventurer Joined: Aug 2007 Location: Oslo, Norway Oddometer: 70	Got the intakes and the oiltemp-adapter last week. After a few "adjustments" everything seems to be ok. I've also pressure tested the fuelsystem and it worked fine without any leaks. The remaining things to do before trying to start the bike is welding on a fitting for the return fuel hose and going through the settings in Tunerstudio one more time. Should be plenty of time for that next weekend I forgot the camera so no pictures this time, will add some later.

02-18-2009, 09:40 AM	#28
JSL Adventurer Joined: Nov 2005 Location: Finland Oddometer: 44

02-18-2009, 10:46 AM	#29
mousitsas Beastly Adventurer Joined: Oct 2008 Location: Athens, Greece Oddometer: 2,144	Ambraa, What AFR are you going to target for your tuning? mousitsas screwed with this post 02-18-2009 at 11:10 AM

02-20-2009, 05:35 AM	#30
ambraa ^OP Adventurer Joined: Aug 2007 Location: Oslo, Norway Oddometer: 70	Hi mousitsas, I will use the recommended values from the megamanual. Somwhere between 12.5 and 13 for high load and 15.5-16 for cruising. I'm hoping that the vacuum signal would be ok for a alpha-n/MAP blend. I believe that would be easier and quicker to tune with the butt-dyno

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