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Since im wraping up my twin turbo camaro project ive been looking for a new project. well this one kind of just fell in my lap.
my friend gave me a suzuki 200dr that needed a lil bit of work.
the carb that was on it has a busted accelrator pump it still runs and runs good but u have to slowly crack the throttle or it dies.
after pricing up a new carb i decided im going to do something wild with this bike
heres a picture of the bike as i started to tear it down
and here is the plan
#1 convert the bike to fuel injection , in order to do this im going to gut the carb and use the carb as the throttle body , i will fab up an adapter behind the carb to hold the injector. and ill have to make up a battery box for a small 12v battery to run the ms and fuel pump
#2 is to fab up a turbo system using a tiny ihi rbh31 turbo this turbo is good for 100 hp , im hoping to get around 75 hp out of the thing , im still doing my research but if i can tap into the engines oiling system this will be the simplest turbo install ive ever done.
if i have to setup my own oil system for the turbo its going to make things complicated but i have a pretty good plan of attack for that.
ill do a low mounted oil resivor below the turbo, and use a mr gasket diesel inline diesel fuel pump as an oil pump to feed the turbo. low mounting the tank will simplify the system as i wont need a return pump to pump the oil from the turbo drain back into the tank. the biggest issue with this system is keeping the oil cool so tank capacity needs to be planed carefully if i want to ride for extended periods of time.
#3 im going to cut and extend the rear swing arm anywere from 6-12 inches , the goal is going to be to extend it just enough that it doesnt try to flip me off the back everytime i get on the throttle , but not extend it so far the bike will only be good for hill climbing
#4 is trying not to kill myself on this contraption once its complete :nono:
anyways ill post pictures as thing progress , i should be ordering up a microsquirt , the turbo, fuel pump , and a few other small items for this weekend
Oh boy. I was wondering when you were gonna post this thread, lol! You got the turbo bug big time. Hope it comes together for ya and you dont kill yourself on the first ride!
It will be interesting to watch you build so dont forget the mass of pics!
holy crap thanks for that link they sell a complete bolt on efi kit for 399 that includes everything , thats cheaper then the route i was going to go
now i just need to see if i can download there tuning software and see just how capable there ecu really is.
the turbo on the other hand i found about 80$ cheaper
No problem they have all sorts of efi kits I build the little honda gx200 for go carts and have been wanting to build a efi stroker stock the gx 200 puts out 6hp the stroker motors do about 26hp
if i where you i would pull the engine find a decent engine less gocart on craiglist and throw it on that with the efi and turbo that thing will scream and have more room for the turbo
and the only problem with going with that much power id be worried about the clutch pack and trans going out if that happens it can cost more to fix that a cars trans
if i where you i would pull the engine find a decent engine less gocart on craiglist and throw it on that with the efi and turbo that thing will scream and have more room for the turbo
i thought about it then i have no place to drive it , would make for a pretty bad *** go cart though
Originally Posted by John4649
and the only problem with going with that much power id be worried about the clutch pack and trans going out if that happens it can cost more to fix that a cars trans
the clutch is one thing i dont know what to do about yet, but being as the bike already has a bent shift fork i was able to pick up all the trans guts on ebay for under 90$'s so i have some spare parts for now
from what i read the clutch in the dr200 is the unit off a much bigger engine/bike so im going to assume it will hold up for atleast some time before it needs servicing
no for the most bada** 2 stroke has to be the yamaha banshee 350 they do the cheetah stroker the amount of power they get outta them is crazy but back on track are you going to freshen the motor up at all
no for the most bada** 2 stroke has to be the yamaha banshee 350 they do the cheetah stroker the amount of power they get outta them is crazy but back on track are you going to freshen the motor up at all
im going to freshen the motor over the winter , i want to get this assembled as fast as i can so i can ride it this summer
I have an old mid-70's TT500 Yama dirt bike I thought about making a type of "Honda Odeysee" years ago...that B*+ch has so much compression! first time I tried to kick it I did not realize it had a compression release! it about flipped me over the bars....
Always wanted to do something with it, missing tank, seat, stator....and parts for these aren't cheap...
wicked project, looking forward to see how it works out
just some stuff to think about, i work in a bike shop and i've seen stuff like this attempted before..
i doubt tapping into the oil system will be hard, but what about oil temperature? not sure how much that tiny little turbo will heat the oil up, but air cooled engines rely completely on air to oil heat exchanging; and you'll be stressing this tiny little engine out already. might want to plan to mount some kind of decent sized cooler on it.
here's my concern with a stock clutch on any heavily upgraded bike.
because of how a wet clutch works, you might barely notice it's slipping and cooking itself.
dead clutch, so what?
well it's a wet clutch, where do you think all that shredded clutch matter ends up?
hell im pretty sure your clutch is right beside your oil pump on that bike (been a while since ive taken one apart)
wicked project, looking forward to see how it works out
just some stuff to think about, i work in a bike shop and i've seen stuff like this attempted before..
i doubt tapping into the oil system will be hard, but what about oil temperature? not sure how much that tiny little turbo will heat the oil up, but air cooled engines rely completely on air to oil heat exchanging; and you'll be stressing this tiny little engine out already. might want to plan to mount some kind of decent sized cooler on it.
here's my concern with a stock clutch on any heavily upgraded bike.
because of how a wet clutch works, you might barely notice it's slipping and cooking itself.
dead clutch, so what?
well it's a wet clutch, where do you think all that shredded clutch matter ends up?
hell im pretty sure your clutch is right beside your oil pump on that bike (been a while since ive taken one apart)
thanks for the input its been many years since ive torn into a small engine , i had a small engine repair class in high school but umm that was a long time ago
been thinking about the cooling issue , im going to run an external oiling system on the turbo with a cooler , i live on the edge of the desert so it can be brutally hot here, so no need to get the engine any hotter then i have to
iirc the oilpump is on the opposite side of the engine from the clutch still really wont matter if the clutch burns up though its going to go threw the whole engine unless the oil filter catches it all
cant find anyone who has turbo'ed one of these since there an old bike so ill just have to see how it works out
havent had much luck with it, decided to ditch the efi system , and do a blow threw carb on it
other then that ive got the bike stripped down and cleaned just really havent worked on it much , prolly wont really get around to it till late fall/winter time
I just started my project up Iv been wanting to do for a few years now I got a old 1987 Yamaha fz600 I traded a 150$ bow for but I'm taking the engine and brakes and putting them on one of those older Manco dingo carts the motor makes 52.3 hp to the rear wheel and 32ftlbs and topped out at 130mph I'm hoping for around 100-110mph outta the cart the cart had a 8hp motor on it so it should be fun if I can I'll have to start my own thread up
heres what she looked liek as of a few weeks ago
i had goten it cleaned up a bit, and found the source of the low compression, the timing chain tensioner was really loose
its just been a combination of being to hot , and no time to really work on it
i think this comming weekend ill load it up in the truck and take it over to the farm were ive been working on my car if my friend lets me
since i havent fixed the transmission i need to be really careful when i start riding it, if u downshift into first gear it just locks up the back tire , wierd thing is in 1st the bike will move backwards but the second u go foward it locks up tight
been trying to get my friend to sell me his kawasaki kf250f but he wont , though he said he could et me one for around 1300 , i really like the honda xr200r of his that ive been riding, he has a few of those as well i may have to see if he will sell me one of those instead, might be cheaper then figuring out whats up with the trans on the suzuki
edit forgot to mention when the turbo goes on this thing i am switching to a thumb throttle
Come to think of it all Iv had has been Yamaha they want to much for the Hondas used around here at one point one person was trying to sell one that was around 5years old for a little under 700$ what it cost brand new
got it over to the shop and stripped down / cleaned some more , but thats it for progress , right now i have some health issues im deailing with so its on hold for a while
50 bucks for clutch discs and steels + springs the basket is another 40-60$'s so not to bad
slightly more for the heavy duty stuff
and looks to be readily available as the 96-09 stuff uses the same clutch setup
im just working with what i have
I built my kid a turbo go cart. I used a old kohler side valve engine and a pull a part turbo. made a intercooler and used a carb from a dr 400. used billet EVERYTHING .balanced ported. cart is good for 80mph . its good to see others with crazy ideas too.
I built my kid a turbo go cart. I used a old kohler side valve engine and a pull a part turbo. made a intercooler and used a carb from a dr 400. used billet EVERYTHING .balanced ported. cart is good for 80mph . its good to see others with crazy ideas too.
some progress tonight on the turbo dirtbike, since i wouldnt get it done in time to ride it before snow starts falling we went ahead and dropped the engine out , and im glad we did as u will see in the pics below
then we pulled the head and cyl ( motor is going to get a custom camshaft from delta cams )
then we started to tear into the engine case as i have to split the case to fix the transmission , the reason im happy i decided to do this now is the clutch disks were fried and i had no idea, wouldnt have been good once i put some power to it with the turbo
the clutch material was actually breaking apart in my fingers, u can see how black they are in the pictures
of course im going to port the head while its off, after looking at the rod in this engine i think im going to stick with just eough boost to bring the hp to around 40 instead of the original 60+ i was going to try for
me and my friend out a few months ago me on the honda xr200r and hime on his yamaha 450
at about the 3 minmark u can see how i broke my fingers
close call with an ford f-350 over a blind hill , had to put the bike into the ditch on the side of the road to avoid the truck , was my fault as i was trying to fly past my friend on the wrong side of the road over a blind hill, anyways could have been much worse , have footage of the actual wreck but because the guy stopped and was in the video i didnt post it
dirt bikes and orthopedic surgeons go together like syrup and pancakes!! hope youre ok
yeah the wreck withth e narrow miss ont he truck was a few months ago,2 broken fingers, sprained knee and mild concusion , im healled up from that , ust have some more serious health issues im dealing with now
should be heading over to the shop soon to tear down the rest of the motor and transmission and see whats broken inside
Subscribed. I'm curious as to what you are going to run for a turbo. I haven't been able to find much online for something under 50hp. I've got a 2-stroke one-lunger in my Ski Whiz I've been contemplating trying to boost. Haha it sure is addicting, isn't it?
Subscribed. I'm curious as to what you are going to run for a turbo. I haven't been able to find much online for something under 50hp. I've got a 2-stroke one-lunger in my Ski Whiz I've been contemplating trying to boost. Haha it sure is addicting, isn't it?
google "rbh31" its the smallest turbo u can get
lol yes it is once u go turbo and relize how easy it is , everything u own is no longer safe as ur first thought is usually oh i can turbo that
got some more work done , mainly i got the transmission fixed and it didnt cost me a dime.
somone over the years has rebuilt the bike and when the reassembled it they put on of the gears on the trans input shaft on backwards , this would cause it to be in 2 gears at once and lock the shafts solid
i need to order up a flywheel puller, timing chain,clutch kit, and piston rings for it , but next weekend i should get the bottom half of the engine back together
heres a better shot of the clutch basket/hub and clutch
and heres the trans mission the gear i have my hands on is the one that was installed upside down
I fabbed my own rear mounted turbo setup on my 1990 Suzuki katana 600 which was oil cooled and had 4 carbs. Everyone said it couldn't be done, 4 months later it was tuned and putting out 4.5psi. Boost was Soo adictting and such a rush when it came on at 8K like a switch. Few weeks later I was up to 12psi and it was just INSANE!
the engine is dead , went to pull the flywheel and somehow the bar we had wedging the crank slipped and i broke the piston , new pistion isnt cheap so im parting the rest of the motor/trans on ebay, i am however keeping the frame .
i happened to get my hands on a hayabusa engine i may try to shoe horn it into the suzuki frame or we have an old quad frame i will cutup and put it on that
it sucks but a piston/rings and timing chain are going to be over 200 bucks , i dont want to spend that much on something im prolly going to blow up
i have decided not to part the rest of the engine though on the chance that i can find a used pistion on ebay or a cheap new one
the hayabusa engine is going on a stretched quad frame unfortunatly i dont think ill be turboing that particular creation as im sure it will have more then enough power to seriously hurt myself as is
maybe i can talk my friend into putting the turbo on his kawasaki 250 or yamaha 450
though both of thos ebikes make over 55hp and already a handfull when u crack the throttle so that may not happen
there is always the honda xr200r's those might be a fun thing to turbo
im also considering buying myself a xr200r so thats always an option
btw this is back on i ended up picking up a street legal xl/xr250r put 4k miles on it so far
been a fun lil bike painted it a nice pearl blue redid the suspension and added an fmf powercore 4 , i also removed the blinkers and brakelight and swapped to an led headlight
this winter im doing a rebuild bore and stroke kit to bring it to around 312cc
and im turboing it
the original plan was to swap the head over to a single carb head but i cant find a good head , so instead of doing a single carb in blow threw setup im going to remove the win carbs and do a draw threw setup with a single 34mm mikuni flatslide carb
heres some pics
the bike after paint and fmf pipe
going to get an aluminum swingarm and extend it 3-4 inches and get a set of cbr600 f3 wheels for street use
stock swinarm on this bike
heres the tiny turbo for it
my buddie gave me a spare engine which he thought was a single carb rfvc so i could use the head and carb setup off of it but its a pre rfvc engine and i cant swap the head onto my dual carb rfvc 250
it is a 4 valve head but its not a splayed valve head like my rfvc head
anyways ill keep ya guys posted this should be a fun bike when im done
36$ score
http://www.ebay.com/itm/400932781046?_trksid=p2045573.m570.l6346&_trkparms=gh1g%3DI400932781046.N101.S1&autorefresh=true
on the rear it bolts in but the sprocket is to far outboard , so a lil machining of the drive hub to move the sprocket inboard is all thats needed , the front wheel when i find one should bolt right in
now i just need a front
wheel will be here today and i also got the cr250 tripple tree and stem ordered , once im sure it fits ill order the front forks ill post pictures up a lil later today
f4i on stock swingarm = to wide
f4i wheel on stock swingarm extended 4 inches = perfect fit
instead of dealing with a spacer for the axle im going to machine myself a new axle 20mm in diam.
the narrower f3 wheel would be perfect, and its the tire that just rubs on the f4i not the wheel , but since i wanted to extend the swingarm anyways it all worked out perfect
05-28-2014, 11:18 PM
