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Kat EFI

pics are back, you did good. All this is way over my head, but I'm enjoying it just the same.
 
Thanks Rich,
I should mention that the Kawa trigger wheel below is actually 24-1 when I was trialling the setup.
I eventually cut 1 tooth off once I was happy with the setup and made it 24-2.
Cheers Andrew.
 
Technical skill level: 10/10. Nice job!

I can't imagine what it took to reverse engineer a modern EFI system and apply it to another machine.
 
80GS1000 said:
Technical skill level: 10/10. Nice job!

I can't imagine what it took to reverse engineer a modern EFI system and apply it to another machine.
Click to expand...

Thankyou,

It does stretch my pea brain a bit but I find EFI is interesting.

And another point to note was if you look at the mounted trigger wheel pictures you can see I had left the original ignition trigger and pickups there. It was just in case I couldn't use the ECU spark/coil controlled side of the EFI (not compatable advance curve) and I had to use the ECU for fuel only then I could use the original Kat ignition setup.

It turned out on the second day of running The EFI setup I did just that to fault find poor starting (turned out to be overly rich mixture [flooding] at cranking/idle) but I did reconnect the Kat ignition back up to eliminate that as the cause.

Cheers Andrew.
 
A lot of this conversion was to use as much of the donor bike in principle so it meant a bit of head scratching to utilise reconfigure its components.

Throttle bodies aside, the other components i.e. fuel pump/trigger wheel/sensor adaptors could all be done differently/neater with a variety of after market/professional made items to do the same job. I don't have personal access to lathes/milling so make do with backyard tools and a invertor welder drill grinder blood sweat tears swearing a VERY patient wifey the usual.
 
I used the complete wiring harness for simplicity, that meant all connections were all compatable for the hand controls, ignition switch etc.
I identified all the connections and I bought a second harness for adding and lengthening the Bandit harness if needed.
oFBII5O.jpg

Shown are the Kat harness on the left and the two Bandit harnesses.
 
The Kat dash tacho uses neg coil style trigger for the signal. The Bandit uses an ECU low voltage signal.
I bought a box of electrickery to 'boost' the ECU signal to drive the Kat tacho.
obDnZrP.jpg

aGyLdf6.jpg

Its alive,
JI1AMH4.jpg

Cheers Andrew.
 
I also added the Bandit o2 sensor to the exhaust.
I now get closed loop fuel injection.
The closed loop will work once the engine is above 50deg. and only in 4th, 5th and 6th (if I had 6th).
vNb0ftL.jpg

Cheers Andrew.
 
GSX1100 dreamn said:
I also added the Bandit o2 sensor to the exhaust.
I now get closed loop fuel injection.
The closed loop will work once the engine is above 50deg. and only in 4th, 5th and 6th (if I had 6th).

Cheers Andrew.
Click to expand...

Why does it run closed loop only in 4-6 gears? Is that because WOT load is generally only used in lower gears?
 
Took 6 months to finish that glass of wine.. Surely not ;) :D Looking good. Is that a tank for the high pressure pump on the left side fed from the tank under gravity? (Edit looked back a bit further & answered my own question...) How did you fix the return etc into the tank, is it a machined piece & you just drilled the tank?

The donor looked pretty clean itself!

GSX1100 dreamn said:
6 months of planning.
C5p1Pt9.jpg


4 days to convert.
Click to expand...
 
Last edited:
The return was a piece of scrap aluminium drilled and tapped for the 1/8 NPT fitting and then nuts and bolts in the tank.
Glasses of wine more like 6 minutes :D and then EFI research not so much !!
Here you can see inside the tank 3 mounting nuts and the long tube is the breather for the pump tank and the open fitting is fuel return.
mzN5QqM.jpg

The opening in the tank
rhuVH5O.jpg

Attached to the tank
9Cm9Aze.jpg

View of the fittings on the bike
6oJF2sW.jpg

The donor bike was a fully functioning running with keys bike 70-80000 km. Atleast I could see the EFI running and do tests if needed before conversion.
Cheers Andrew.
 
Wanting to keep my Kat cooler, added another cooler.
When cold the lower oil gallery plug had 3 psi at idle and 10 psi at 3000 rpm.
exhaust oil gallery plug had 0 psi at idle and 1 psi at 3000 rpm.
used an existing cooler I had.
After a week of commuting it seems 5-10 deg cooler, it is slower to rise in temperature and drops more rapidly when hot.​

eqMl31p.jpg


wSK2G21.jpg


meImmC3.jpg


BEhnTVI.jpg


gzYfhR3.jpg


Gallery plug size,

O6pinxy.jpg
 
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