Sooooo last week I did my motorbike carb conversion. Here is what I did.
Got all my bits;
GSXR 750 Carbs jetted for my 16v
RamAir filters
Custom stainless Manifold
Facet Silver top fuel pump
Filter King Fuel Regulator
fuel pressure gauge
Oil Catch can
Universal Choke cable kit
2 x solder-less nipples
1 x 8mm T-Piece
Couple of meters of 8mm fuel pipe
Lots of small jubilee clips and some big ones.
Engine bay before I started;
It looked cool but fuel injection isn't for me + all that inlet manifold / intake pipe was taking up too much space for my liking.
So, I started by removing anything to do with the fuel injection / air which was basically the inlet manifold, injectors, airbox and fuel matrix. If you un-bolt everything it all pretty much comes off in one.
This is what I was left with under the bay;
I then started by jacking the back of the car up and removing the old fuel pump. Not being technical I have to look at a manual and have a chat with my bro as basically the facet pump is very basic. It has fuel in, fuel out and a live where as the old pump had a live, earth and had fuel in, fuel out but this also then went into something else that split the lines in two...... anyyyyywaayyyy to cut a long story short the current engine had a fuel return reservoir which was now no longer needed.
So remove you old filter /reservoir. Mount the new pump using one the the bolts where your old pump was. I also at this point nipped the end of the earth cable and attached a eyelet so I could bolt this to the body when attaching the pump. Run the pipe coming from the prime pump (square white plasticy looking thing) into the fuel in. Use on of the lines running into your engine bay and connect this to the fuel out on the pump. You may need to use some new fuel line for this bit. I then block off the fuel return line that goes into the prime pump with a big bolt and jubilee clip. Then I connected the live up to the pump.
Once that was done I then moved into the engine bay.
First of all I fitted the manifold. I used my old gasket as I forgot to order a new one. If you do this then make sure you use some instant gasket too so you don't get any air leaks. Ideally though just remember to buy a new gasket.
I then mounted the carbs to the manifold using some rubber pipe and jubilee clips. I'm not sure on the diameter of the pipe as I got all of this with the carbs already BUT just make sure it won't collapse when being sucked.
I then mounted the fuel regulator. I mounted mine down where the air box used to be (as there were already some little holes) using a little custom made mount (basically a flat bit of metal with some holes drilled in it.
I then worked out which line I connect the pump up to under the car. This was easy as I knew i had used the old fuel feed and I knew which pipe originally went into the fuel metering matrix. If you don't know this then you can just turn you ignition on and see which one is pissing out fuel.
I then connected the fuel line to the fuel regulator which I did using some fuel line and jubilee clips. The fuel lines i had coming into the bay were copper so I had to use rubber fuel line to make them reach to the regulator. Nice and easy.
I then ran a line out of the regulator into a fuel pressure gauge (this is needed so you can set the pressure right. You can buy regulators with these built in but again I got all of mine with the carbs for cheeps :) ) I then ran a line from the gauge to the carbs.
The carbs have two fuel lines going in so you will no need to fit a T-Piece to split your line in two. I then fitted some more fuel line to the T-Piece and ran them into the carbs.
I then needed to attach the accelerator cable. I read few different mays of doing this like running a push bike brake cable etc but dont bother. Simply cut the end off your current cable and attach a solder-less nipple. It takes 10 minutes and fits much nicer. The lad I bought the carbs off had made a little bracket to sit the accelerator cable in so it sat nice on top of the engine. He just made that from the bracket that used to hold the cable and bent it to fit;
It's a nice cheap, simple bodge but looks tidy, mounts easily to the back of the block where it used to mount and does the job perfect.
Next was attaching the brake servo line to the side of the manifold which I did by using some of the pipe i had removed when taking all the manifold / airbox off. This again was nice and simple.
I then mounted my oil catch can near the radiator and ran the oil breath pipe to it. You can add an extra pipe on the catch can with a filter or something but for me personally I am only using it so the shit doesn't go directly onto the road.
So with all that done this is how the engine bay now looked;
Everything was now in place meaning I could try and fire the old boy up. Here is the first start...... remember what once your fire up you will need to adjust your fuel regulator to 3 psi (below is a video, just click it) ;
You can hear it sounds bit funny but that was because it was sucking in air from where the carbs were mounted plus it wasn't really setup.
Here is how it looked with the filters on;
Here it is just ticking over later that night (below is a video so just click it);
I still need to go over everything yet tide it up, like cut out all the old electrical bits that are in the bay and insulate them under the dash. Fit the choke cable (not essential but if I want to drive it in winter I will need it) and generally tidy it up and go round making sure everything is nice and tight etc.
I have read a few forums etc and people are always asking about the ECU / dizzy etc. All your ECU is now doing is controlling your spark so only attaches to the dizzy. I think i may need to adjust my timing slightly but thats it you don't really need to touch any of that.
At the mo I think it is still sucking in air as it aint quite running right BUT it runs.
We did set it up ourselves but I am going to take it on a rolling road and have it done properly and see what bhp it's at.
I must say though, off the mark it is something else, it's sooooo responsive it's unreal =)
Once it's all setup I will post some more video's of the sound and let you now the BHP etc.
[REMEMBER PEOPLE I AM 100% AMATEUR SO DON'T KNOW LOADS BUT IF YOU ANY QUESTIONS THEN FIRE AWAY AND I WILL TRY MY BEST TO ANSWER]
