Turbocharging by ninja on minimum wage - Page 3 - Kawasaki Forum :: KawasakiWorld.com
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post #31 of 94 Old 08-20-2017, 09:56 AM
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I ran my exhaust through the stock location and all the way back to the rear of the lower fairing but dumped it out to where if I ever blow a turbo or have an oiling issue it all dumps behind my foot and off to the side of the rear tire.








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post #32 of 94 Old 08-21-2017, 04:00 AM Thread Starter
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I do recommend you direct the exhaust away from the side of the oil pan for a couple reasons.
Thanks for the words 2fat. I thought I mentioned this but maybe not lol! The exhaust is not finished - Ill be running it into 2x mufflers on the right hand side. The only reason I painted it now is so it doesnt rust in the meantime.

Why run mufflers and why 2 of them you ask? Because its going to be a fully legal street bike and I need to get it engineered, so it needs to be quiet. And Im using two mufflers because 1 doesnt flow enough.
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post #33 of 94 Old 08-22-2017, 11:30 AM
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Great work on decapping the stock injectors. You're the first I've heard of that has done it to a ZX12R or even any bike. KZScott mentioned something to me the other day about a guy he knew who could modify stock injectors for high flow, I suspect it's the same thing. I've heard the terminology thrown around in the GM LS(x) world last year or so but never really paid attention to it. After I saw your post I dug a little and found some very promising stuff regarding it. Definitely get yours flow tested and let us know the results! OE zx12 injectors can be had for pretty cheap, so this could be a potential huge budget upgrade for people (that need huge injectors).

Here is a well known guy in the LS world that has a nice little video showing the procedure for anyone else interested...

https://sites.google.com/site/sloppy...fuel-injectors
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post #34 of 94 Old 08-22-2017, 01:01 PM
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Great info. Thanks Hibs!


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post #35 of 94 Old 08-23-2017, 12:56 AM Thread Starter
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Here is a well known guy in the LS world that has a nice little video showing the procedure for anyone else interested...

https://sites.google.com/site/sloppy...fuel-injectors
Haha that's exactly where I got the idea from! I used an angle grinder with a cutting disc - using the flat part of the cutting disc very very lightly which works well because it grinds very slowly, is flat, and is actually quite accurate.

Another mid week update.

I received all the fittings necessary for the oil feed. I thought I would share in detail what the fittings are because I couldn't find this information when I was researching turbo ZX12's.

From left to right, crankcase to turbo:

3/8" BSP to 1/4" BSP reducer, 1/4" BSP to 4AN male to male adapter, 4AN push on/push lok fitting, 2ft of 400 series hose (1/4" inside diameter, high pressure, oil/fuel proof), 4AN push on/push lok fitting, 4AN to Garrett GT25/28/30 turbo adapter with 0.035" oil restrictor (not actually sure on the threads on the turbo oil feed, but it looks metric)

Hopefully someone from the future reading this, wanting to turbo their ZX12, will now know whats needed for an oil feed.


How good is this; its like kawasaki knew people would want to turbo these things and so they installed a bung that supplies pressurized oil! No tee-ing off oil pressure sensors needed here! Thank you Kawasaki, you made my life easier. This is the plug, near the sight glass. It's 3/8" BSP thread.

Last edited by YoWattup; 08-23-2017 at 01:00 AM.
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post #36 of 94 Old 08-23-2017, 05:59 PM
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Hahahahaha. I've not heard that one. I like it.

I've had a closer look at the air filters and decided to leave them be - they have a pretty good seal on them and I think they would hold my goal of 7psi. If not - Sikaflex

A few small updates:


I took a look at the throttle body bolts in my side-quest to seal the airbox. These thingymajiggers are what the throttle bodies fasten onto and are underneath the airbox/frame on the outside. I welded these nuts so they are airtight around the base. I will put rubber washers between these and the airbox on the outside. Finally I will use thread sealant and IF nothing fails it will be airtight.


.
i feel like you put a lot more effort into this area than required. on my race bike(500+hp) i tapped the holes that the rubbers go in m6. i then pressed the ends flat where they used to go into the rubbers(you can hammer them if you dont have a press) i put a very light coat of silicone around each hole and bolted the stacks in, then bolted the nut rail ends to the tapped holes. lock tight on the threads is boost proof


good luck with the decapped inj with gas. they would be good for e85 but your driveability will be poor with such big inj. its hard to find a balance between big enough and too big when dealing with just 4 inj. 500-550cc is about the limit on a 12 with gas before you start having issues. FYI the stock injectors will support about 300 hp on gas IF you use an FMU style fuel pressure regulator (6:1) and a high pressure pump.
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01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #37 of 94 Old 08-24-2017, 04:34 PM
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btw i noticed the rail modification for the second fuel fitting looked a little rough. holes for o rings are typically not a drilled hole as the rough edges will eventually damage the o ring and can cause potentially dangerous leak. a very easy solution in your case is to tap the rail for a 1/4 npt fitting. easy to find one for 5/16 (8mm) hose

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #38 of 94 Old 08-27-2017, 01:17 AM Thread Starter
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btw i noticed the rail modification for the second fuel fitting looked a little rough. holes for o rings are typically not a drilled hole as the rough edges will eventually damage the o ring and can cause potentially dangerous leak. a very easy solution in your case is to tap the rail for a 1/4 npt fitting. easy to find one for 5/16 (8mm) hose
Thanks Scott, I appreciate the concerns. I actually sealed it 3 ways - the o ring, a red gasket-style washer (not sure on proper name), and sealant around the flange. I am confident it wont leak and I will prime it a few times before I start it as well as keeping eye on it. Two things I don't half-ass is fuel and brakes.

I ordered these mufflers from good old ebay for $40 a piece. They are full stainless. I fabbed up mounts for them. As I mentioned before I was going to run them both on the right hand side but that was just crap. So there will be one each side like this. I think it looks kinda badass. As good as stainless is I think I will still paint them black. Has anyone guessed my favourite colour yet?









Gotta get some more 2 inch piping as I'm fresh out. Then I can finish the exhaust. Also get these injectors flow tested, put the throttles back in, retune the power commander and hopefully fire her up with the turbo for the first time! I'll be very busy in the next few weeks so updates may be more scarce.
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post #39 of 94 Old 09-03-2017, 11:16 AM Thread Starter
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Alright. Got the 2 inch exhaust pipe and a donut. Made the rest of the exhaust. All I gotta do now is make a couple more mounts and weld the hooks on for the slip-on springs. Then paint BLAAAACK and maybe wrap it near the sump.








The stand hits the exhaust on the left hand side. Solution: I dont care. It still functions fine.


Anyone know what these lines are for? I just realised I didnt chase them down to see where they go, yet managed to take pictures of them. I think I had a few too many beers that day. Can I use one or both for the return since my bike doesnt have a return line?


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post #40 of 94 Old 09-04-2017, 08:06 AM
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you cant use those as a return, one is a vent and the other is for when you spill gas at the cap

put a bulkhead fitting in the sump. with a tube that returns the fuel AWAY from the filter sock. you dont want aerated fuel going to the pump.

01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #41 of 94 Old 09-05-2017, 07:29 PM
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Bike looks cool! I didn't notice if thos was gonna be a pure drag bike or street/strip. I like the look of where you put the turbo, but a word of caution about clearance while leaning.

If you read my turbo build and saw the exhaust I made the first time around. It was a 180* loop from the turbo, back under the bike. That exhaust stuck out the right side just a little tiny bit too far and put me down while making a turn.

Take it for what it's worth but if it drags and you aren't quick enough to catch it you will go down. Awesome build, keep up the good work.
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post #42 of 94 Old 09-07-2017, 01:44 AM Thread Starter
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Originally Posted by KZScott View Post
good luck with the decapped inj with gas. they would be good for e85 but your driveability will be poor with such big inj. its hard to find a balance between big enough and too big when dealing with just 4 inj. 500-550cc is about the limit on a 12 with gas before you start having issues. FYI the stock injectors will support about 300 hp on gas IF you use an FMU style fuel pressure regulator (6:1) and a high pressure pump.
Not sure if I mentioned it but it will be on E85. I am strongly against using FMU regulators because they put too much pressure on the whole fuel system and its a blowout waiting to happen. Fuel leaks are not cool.

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Originally Posted by 1990sss10 View Post
If you read my turbo build and saw the exhaust I made the first time around. It was a 180* loop from the turbo, back under the bike. That exhaust stuck out the right side just a little tiny bit too far and put me down while making a turn
Yes I saw yours. Great build. What was the top end like with such a small turbo? Did it still make power up at high rpm? I imagine it would be a mid range monster. I noticed you seem to have used mandrel bends for your exhaust system. I use donuts because the bend radius is much smaller and more suited to bikes. Check em out

Mid week shenanigans

Little quick n dirty trick I used to keep heat from the manifold and turbine housing from destroying the rubber oil feed line: Wrap it with fibreglass header wrap, then wrap that with aluminium tape. Ive done it before with my car's throttle cable because its rests on the wastegate. Works great. Looks like a stick of green kinda hahaha.





Also fabbed up a mount for the middle of the exhaust, as well as the hooks for the slip on springs. Next pics of the exhaust should be finished and painted black.
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post #43 of 94 Old 09-07-2017, 01:46 PM
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you should be fine with E85. FMUs have gotten a bad rap over the years with a few problematic designs. the newer begi and the rcc fmu doesnt have the issues the shim style version(and cheap chinese kock offs) had. as far as pressure goes, you will see about 90 psi of fuel pressure on a stage 1 style kit with the fmu. a properly designed system will be using parts that are typically a 300 psi rating ( at least the ones I do at work and home are) all of the rcc gen 1 hayabusa stage 1 and zx14 stage 1 kits come with the fmu we build in house and we dont have issues with leaks or blow outs. a race kit with a 1:1 regulator will see 76 psi of fuel pressure at 33 psi of boost. another 14 to 90 isnt that big of a deal with the right parts. (just to clear up any misconceptions)
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01 ZX-12R 8.84 @ 156.3 on dot tires, NA.... turbo 8.47 @ 164
00 ZX-12R 8.62 @ 165.2 no bars, slicks, 55 shot... turbo 8.32 @ 173
00 ZX-12R 1: 222.046 1.5: 226.390 Worlds Fastest NA Kawasaki
00 ZX-12R street turbo 1: 227.9 1.5: 234.1
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Worlds fastest ZX-12R CMG Racing RCC Turbos
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post #44 of 94 Old 09-09-2017, 10:06 PM Thread Starter
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Another weekend of working on the Ugly Duckling (thats my name for it) done and dusted. Heres some updates in chronological order.


Exhaust is painted and pretty much done. I kept the mufflers unpainted for now. Might paint them later.







Started on the oil return. Draining the oil here so I can take the sump off and have a look at the inside. In the grass of course Luckily the weather is faaaaaaaaaantastic right now here in Aus.



Gonna weld the return to the sump here, in this fashion.





Also made a mount for the fuel pressure regulator which tucks it away nicely. Not finished (read: painted) yet.






You may notice I use studs + nuts instead of bolts for some fittings (like in this instance and the middle exhaust mount). I do this mainly when screwing into aluminium for a few reasons. One is because a stud can use 100% of the available thread in a closed-in boss, a bolt cannot use all of the available thread if it is to tighten properly, making the stud stronger. Secondly, when you tighten the nut on a stud, there is only longtitudinal friction acting on the aluminium threads, becuase the stud is not moving. If it were a bolt, there would be longtitudinal and rotational friction on the aluminium threads, making it much more likely to strip.

When inserting the studs into the aluminium, always use loctite on studs and you only need to hand-tighten them. I simply cut the heads off bolts to make studs.

KZScott, or anyone else who knows, exactly which bulkhead fitting should I use for the fuel return? I'd like to use 8mm fuel hose but that would be -5AN which is not very common. Also there is not much clearance when I lower the tank, which means Ill have to use a 90 degree fitting which narrows my selection further. Should I stick to 4AN? 6AN? Any help here is appreciated. Thanks.

Im thinking this

http://www.ebay.com.au/itm/Speedflow...IAAOxyBvZTViJr

Combined with this

http://www.ebay.com.au/itm/Speedflow...MAAMXQydtTNOzJ

Should work? Or is that not enough flow when combined with a beefy fuel pump? 6AN/10mm hose seems like it'd be overkill
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Last edited by YoWattup; 09-09-2017 at 10:39 PM.
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post #45 of 94 Old 09-10-2017, 03:28 AM
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she might look like an ugly duckling but will fly like an eagle
we just recently bought a BMW x1 turbo diesel these turbos are a twin scroll turbo and would suite a bike (not the diesel one necessarily) but they work with very little lag as two exhaust ports feed separately to the other two great application for a bike a little extra plumbing Craig

if anything goes wrong check the battery
no longer a rider but still an enthusiast
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