Suzuki Gs850 EFI Conversion

[rjteeter]

Don't think I was dumping on you, I wasn't. But I am familiar with solid modeling and CNC work and I realize that machines don't run for free and costs add up quickly. It is just a fact of life and cannot be avoided.


Mark

I don't think you were dumping on me but you can if you like, I don't mind

I had some major computer and software issues (as well as the usual operator error, beer drinking and video games) and fell way behind my original schedule but the runners are done! I've diverted from my original order of operations and I'd like to tackle my crank trigger wheel next.

[93Bandit]

Those look great! Sidewall thickness looks thick, are you going to trim them down?

Also, I don't see tabs for bolting them to the head like the boots have. Whats your mounting strategy?

[rjteeter]

Those look great! Sidewall thickness looks thick, are you going to trim them down?

Also, I don't see tabs for bolting them to the head like the boots have. Whats your mounting strategy?

They are final size. They adapt GSXR Throttle bodies. The outside diameter matches the GSXR throttle bodies. I will mill a flange for mounting.

[93Bandit]

Oh gotcha. Looks great.

[salty_monk]

Very cool project...

[rjteeter]

Welp, as usual I went a little eccentric in my design and beyond my capability but I have another overly involved prototype, lol. Lots of photos to follow...

I started off with some stock which I had to turn down a smaller diameter section on my lathe, to fit in my tiny 4th axis chuck on my mill:


Then I burned up about $100USD in end mills trying to mill steel (I am more familiar with aluminum):

[rjteeter]

I ended up with a 24-2 adjustable timing wheel and stand off that bolts up to the Suzuki GS crank with the stock bolt and crank nut and fits under the stock timing cover:

[rjteeter]

Past my typical milling mistakes I made one obnoxious design flaw (and yet again beyond the design flaws created when I designed this before receiving all necessary specs needed for the hall effect sensor I chose to go with), The crank/wheel mounting bolt/crank turning nut mate up the the trigger wheel surface. This means if I want to adjust the trigger wheel I need to loosen the crank bolt. I should have had the stand off center/alignment ring larger and protrude fully through the center of the trigger wheel so the crank bolt/nut mate to the stand off and not the trigger wheel. I will probably re-design and re-mill at some point any way because I believe I can make the wheel smaller and maybe go for higher tooth count. Also might design a beefy cover replacement as, as it sits this just looks like an 11k rpm projectile waiting for its moment to sever a limb. - Notes to future self.

[Rich82GS750TZ]

Thought of this. Name the movie.

[Dogma]

Thought of this. Name the movie.

It's been a while. Probably since TBS ran them every night for two weeks back in the mid nineties. Always something on to watch for those two weeks. I think that one was Moonraker.

[rjteeter]

Intake manifold flange is milled! It does need to be adjusted and taken back to mill as the insides hit the timing chain extrusion on the head leaving me unable to mount it. Sadness fills my heart.

[rjteeter]

Hey all, thanks for the pictures. I've been back to work for a week now (third shift GROSS, going back to second shift next week. I'm currently working on the adjustable linkage at center, between the throttle bodies. I have a design and if I get motivated I'll post an image. But I'm curious as to what other people would come up with/engineer. I'll try to verbally illustrate what I'm after; I have 4 throttle bodies - The two sets of outer throttle bodies share one single butterfly shaft (that's two shafts, one for each two; outer throttle body sets). Between the center 2 throttle bodies (cylinders 2 and 3) I need a simple but adjustable linkage to connected the butterfly shafts. My creativity is spent and I could use some help here. This is actually a pretty silly request as the stock style would work but without turning it into cad or having a drawing present I'm just lost. I think I have an image lost in my head but I can't continue until I figure out what I want/need.

[Burque73]

Maybe something in this design will inspire you.

Steering linkage for an RC six wheel formula one car.



Here's the site it was on.

[rjteeter]

Maybe something in this design will inspire you.

Steering linkage for an RC six wheel formula one car.



Here's the site it was on.

Roger, thanks for the thought. This is a pretty interesting setup but I have a vague starting point and can't find any improvement from my starting point based off this ( I will re-evaluate later, though). At any rate, drift season is upon us and I have shifted my focus on getting my drift car ready. I will return to this project later this year or as resources allow.