DarrenW
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| posted on 28/11/06 at 11:01 AM |
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Bike carb conversion is go!!
Game on. Just collected my ali manifold at the weekend. I ordered it in its raw welded state so now busy smoothing it all off inside with die grinder.
Next job is to strip the carbs (ZZR1100) down, clean them up and re-assemble. Drill jets out (ill try 170 for starters) and set needles to mid point.
Ill probs use mech pump at first. Ill also have to work out how to fit the filter (must remember to collect). Might need choke cable connecting up and
different throttle linkage.
When you measure carb choke size, is this basically the ID where the butterfly sits? If so the carbs are a smidge over 40mm.
Only problem right now is the tube i bought is too small. I need some with ID 47mm. Ill try fitting the carbs first and get it running on the
electronic dizzy and then swap over to megajolt afterwards.
Ill have to get Guiness to remind me how to connect the carbs up to the fuel - 2 sets of pipes i can see, i assume 1 set is for hot water (if so is
this needed?)
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jos
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| posted on 28/11/06 at 11:26 AM |
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Who did the manifold Darren - Bogg Bros???
.: Motorsport / motor racing circuit / track wall art Apex Traxs :.
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DarrenW
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| posted on 28/11/06 at 11:40 AM |
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No, deneo. It was considerable cheaper than Boggs as i asked for it in its welded state rather than all polished up. Im not bothered about the bling
factor as long as the inside is all smoothed out.
Dene does ali fabrication as a hobby and doesnt have that much spare time as he works away a lot so i had to be patient.
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jos
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| posted on 28/11/06 at 11:47 AM |
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Has he done one for R1 carbs, did he need your carbs as a template
.: Motorsport / motor racing circuit / track wall art Apex Traxs :.
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DarrenW
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| posted on 28/11/06 at 12:15 PM |
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Yes - he needed the carbs. As said he does general ali fab and not specifically carb manifolds. I obviously havent fitted mine yet so need to do that
and check the fit.
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02GF74
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| posted on 28/11/06 at 01:51 PM |
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so where are the pics 
re: driolling - do you know what you are doing? maybe run them as they are and if not right, drill out since it is easier to drill a bigger hole than
to undrill a smaller one! (my local faster place does drills in .1 mm increments if you are stuck for size).
quote:
Originally posted by DarrenW
... Drill jets out (ill try 170 for starters) and set needles to mid point.
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flak monkey
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| posted on 28/11/06 at 01:54 PM |
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Bet you are chuffed Darren, I know you have been waiting for your manifold to come 
The actual drilling of jets is a doddle if you have a lathe. Just see what you have got to start with, then if its running lean open them out a bit.
The only true way to tell is to get it on a rolling road. What is more difficult is getting the size right.
If you drill them out too large you can fill them with solder and re drill them smaller. (Assuming they are made of brass or similar)
David
Sera
http://www.motosera.com
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DarrenW
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| posted on 28/11/06 at 02:49 PM |
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quote:
re: driolling - do you know what you are doing?
I hope so - im a time served toolmaker, production engineer for 6 years and automotive project manager for last 6 years, and in my spare time have
worked on cars for the last 15 years + so should be OK.
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Guinness
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| posted on 28/11/06 at 08:15 PM |
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evenin'
you called?
 
Description
Any help?
Fuel goes in the bottom pair, the top pair t together and back into the airbox, the hot water is the sides. If it is easy to plumb the warmer in, I
would, as it will warm up quicker in the winter / need less choke. Also if you have the carbs sticking out the side of the engine and no 1 does ice
up, you may run lean on that cylinder?
Mike
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JoelP
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| posted on 28/11/06 at 08:15 PM |
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i drilled my zx9 carbs to 1.65mm, seems (seemed  ) right for it. BBN do drill bits in 0.05mm increments.
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mcerd1
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| posted on 29/11/06 at 10:09 AM |
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quote:
Originally posted by Guinness
Fuel goes in the bottom pair, the top pair t together and back into the airbox, the hot water is the sides. If it is easy to plumb the warmer in, I
would, as it will warm up quicker in the winter / need less choke. Also if you have the carbs sticking out the side of the engine and no 1 does ice
up, you may run lean on that cylinder?
I assume its a similar setup for the Keihin CVR types ??
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DarrenW
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| posted on 29/11/06 at 11:41 AM |
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Thanks for the photo Mike - mucho appreciated.
Someone once mentioned that a mod on these carbs is to fit a different top to allow the slider to move further up - does anyone have details?
If you use dynojet needles am i right to assume starting in the mid point first.
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Guinness
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| posted on 29/11/06 at 11:52 AM |
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Darren
The carbs I gave you are flat topped already. The restricted carbs have a dimple / depression in the middle.
HTH
Mike
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DarrenW
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| posted on 29/11/06 at 11:54 AM |
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Cheers Mike, it just keeps getting better.
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