RempageR1
Well-Known Member
Hi,
After reading this (Electronic fuel injection- CV carbs to TBI) topic, I became interested in modifying my Gen-1 into a fuel injected bike. To do it properly, I wanted to use a Wideband Lambda sensor, a MAP and TPS sensor and some other bits and pieces.
The reasoning behind doing the injection mod is personal: I thought it would be a cool challenge to take on during this COVID-19 time. I do not expect any torque or power gain, although one benefit will be the tolerance for E10 fuel. In this topic, I will try and provide all the technical details of what I`ve done so far and will also ask one or two questions. I would greatly appreciate any feedback and remarks on the technical details, and would like to refer anyone to the topic mentioned above for the discussion about the usefulness of adding fuel injection to the Gen-1 so this topic remains on-target and a technical discussion. Thanks!
To not spend an enormous amount of money on this project, I want to use off the shelf equipment as much as possible. I also do not have machinery to make my own parts so all of it has to be done with basic tools. Also, this should not be a one-way mod. I want to make sure I can go back to stock if I want to so I will keep original parts and cables in place.
This project will be carried out in four phases:
Step one: Throttle bodies.
I did not want to spend an enormous amount of money creating a custom set of throttle bodies so I initially wanted to order the injector sleeves from Jack (roadstercycle.com) as explained here:
Yamaha Vmax Fuel Injector CV Carb
Since he didn’t respond I decided to do some homework of my own. I looked at compatible throttle bodies and finally bought a set of Honda VFR1200 (2010+) throttle bodies including their injectors. This is a similar engine (1200cc V-4) so the theory is that injectors etc, should be a match. This set looks something like this:
The funny thing is that this set is fly-by-wire. On the left side of the picture, you can see the mount for the throttle cables, on the right side, the servo is shown opening the valves (so it`s fly by wire for about 15 cm
). Going fly by wire was one bridge too far, so I the plan was to ditch the servo and reuse the pulley from the TPS and mount that to the place where servo is now positioned.
The picture below shows the injectors. The cool thing is that the fuel injectors and their fuel lines are modular:
Off course, the throttle bodies are not aligned with the Vmax, so it`s great that the set is modular so in the end, the only thing that needs to be replaced is the pipe shown here between the injectors.
Next, I removed the servo and pulley:
And added some threats so I could mount the pulley:
So far so good! But when I fitted the throttle bodies, I found out that the space between the front and back cylinders is too small so it would never fit…. After some scratching my head, I found out that if I mounted the front ones in the back, and the back ones in the front, it would fit (with the fuel rails now being on the front and back of the throttle bodies and no longer in between). The spacing for the (now) rear throttle bodies is near perfect, I just added two rings and that was one. The front ones needed to be widened by about 5cm, so I needed to make new brackets such as this:
For now, I just used some galvanized steel, if it will all work according to plan later on, I will make them from stainless steel.
From the TPS, I added the spring behind the pulley as an extra safety precaution:
To keep the rear throttle bodies as original as possible, the only thing required is this small bracket that rotates the connection point 180 degrees. The bushes for the linkage between back and front throttle bodies are made from rivets which just needed to be sanded down a fraction.
And the finished product looks something like this:
Another challenge was the diameter of the throttle bodies. Initially, I want to run this set using the original manifolds (while for now disabling the Vboost). If it all works as expected, I will later add a new set of (dramatically wider) manifolds. For now, these are used:
After reading this (Electronic fuel injection- CV carbs to TBI) topic, I became interested in modifying my Gen-1 into a fuel injected bike. To do it properly, I wanted to use a Wideband Lambda sensor, a MAP and TPS sensor and some other bits and pieces.
The reasoning behind doing the injection mod is personal: I thought it would be a cool challenge to take on during this COVID-19 time. I do not expect any torque or power gain, although one benefit will be the tolerance for E10 fuel. In this topic, I will try and provide all the technical details of what I`ve done so far and will also ask one or two questions. I would greatly appreciate any feedback and remarks on the technical details, and would like to refer anyone to the topic mentioned above for the discussion about the usefulness of adding fuel injection to the Gen-1 so this topic remains on-target and a technical discussion. Thanks!
To not spend an enormous amount of money on this project, I want to use off the shelf equipment as much as possible. I also do not have machinery to make my own parts so all of it has to be done with basic tools. Also, this should not be a one-way mod. I want to make sure I can go back to stock if I want to so I will keep original parts and cables in place.
This project will be carried out in four phases:
- Find throttle bodies and see if they can made to fit.
- Select and get to know the injection system.
- Install all electronic parts on the Vmax but keep running the carbs. This tests the new controller and ensures it doesn’t crash or show strange behaviour. Here I can test the Wideband Lambda sensor, temperature sensor, TPS and MAP, and the RPM sync. The cool thing is that all of this can be displayed using an Iphone App, more on that later.
- When all is well, install the throttle bodies and fuel injection pump, regulator, filters etc. and see what will happen .
Step one: Throttle bodies.
I did not want to spend an enormous amount of money creating a custom set of throttle bodies so I initially wanted to order the injector sleeves from Jack (roadstercycle.com) as explained here:
Yamaha Vmax Fuel Injector CV Carb
Since he didn’t respond I decided to do some homework of my own. I looked at compatible throttle bodies and finally bought a set of Honda VFR1200 (2010+) throttle bodies including their injectors. This is a similar engine (1200cc V-4) so the theory is that injectors etc, should be a match. This set looks something like this:
The funny thing is that this set is fly-by-wire. On the left side of the picture, you can see the mount for the throttle cables, on the right side, the servo is shown opening the valves (so it`s fly by wire for about 15 cm
). Going fly by wire was one bridge too far, so I the plan was to ditch the servo and reuse the pulley from the TPS and mount that to the place where servo is now positioned.The picture below shows the injectors. The cool thing is that the fuel injectors and their fuel lines are modular:
Off course, the throttle bodies are not aligned with the Vmax, so it`s great that the set is modular so in the end, the only thing that needs to be replaced is the pipe shown here between the injectors.
Next, I removed the servo and pulley:
And added some threats so I could mount the pulley:
So far so good! But when I fitted the throttle bodies, I found out that the space between the front and back cylinders is too small so it would never fit…. After some scratching my head, I found out that if I mounted the front ones in the back, and the back ones in the front, it would fit (with the fuel rails now being on the front and back of the throttle bodies and no longer in between). The spacing for the (now) rear throttle bodies is near perfect, I just added two rings and that was one. The front ones needed to be widened by about 5cm, so I needed to make new brackets such as this:
For now, I just used some galvanized steel, if it will all work according to plan later on, I will make them from stainless steel.
From the TPS, I added the spring behind the pulley as an extra safety precaution:
To keep the rear throttle bodies as original as possible, the only thing required is this small bracket that rotates the connection point 180 degrees. The bushes for the linkage between back and front throttle bodies are made from rivets which just needed to be sanded down a fraction.
And the finished product looks something like this:
Another challenge was the diameter of the throttle bodies. Initially, I want to run this set using the original manifolds (while for now disabling the Vboost). If it all works as expected, I will later add a new set of (dramatically wider) manifolds. For now, these are used:
