Mikeb's Builds Thread

[mark]

Originally Posted by MikeB

Well here it is finally.
The first start vid!

http://www.youtube.com/watch?v=LJ53Gd4fa14

Its actually its second start, but first start with the new manifold and bike carbs.

It needed a lot of choke on the carbs but seemed to run nicely, a lot better than the old carb and the exhaust manifold didn't glow bright red this time!

First mod to the carbs will be adjusting the idle mixture to get it running without lots of choke, then not sure what to do for IVA. Leave it or open up the jets to 1.5mm or 1.6mm.

I've also laid my loom in place and will be connecting up the ignition , so it will start off the key next time (super cool!)

Mine passed iva on the standard jets with flying colours, obviously you cant drive it hard up in the revs like that as it will be lean

After a good few runs on a rolling road I ended up with 180 jets, 170/175s were safe too mixture wise but 180s had a touch more power

Still would have passed emmisions tests if required with the bigger jets in

The cvh head doesnt flow very well so doesnt suck very well hence the quite large jets for a modest power output

[will_08]

Well done Mike, looks a tidy build so far you should be proud

[HandyAndy]

Congrats on the first ( 2nd in vid ) start up, sounds great
A major milestone of anyones build,

cheers
Andy

[MikeB]

Yeh the builds really starting to come together now.

Mark, did you do anything to the carbs to get the engine idling as mine needs lots of choke at the minute, i was planning on just adjusting the idle mixture on each carb.

Mike

[mark]

Originally Posted by MikeB

Yeh the builds really starting to come together now.

Mark, did you do anything to the carbs to get the engine idling as mine needs lots of choke at the minute, i was planning on just adjusting the idle mixture on each carb.

Mike

Mine ran pretty well as they came off the bike

If you havnt already make sure the idle screws under the carbs are all in the same position by screwing them all home then back out the same ammount (approx 3 turns should be somewhere near)

Running without a silencer/no airfilter and no coolant isnt going to give you a steady idle with no choke after 30seconds running

I suspect once you have coolant in and can let it run for a while with the throttle stop adjusted accordingly it will idle anyway

When you get around to fitting an air filter i would change two of your trumpets also so they are all the same length

Something else to consider with the zx6r carbs is the heating circuit underneath with the little coolant pipes

Every man and his dog will tell you, you dont need to use them but i would suggest you do! My carbs froze up in temps nowhere near freezing point (due to fuel atomisation having a refrigerant effect)

I know the same happened to Spuds car with these carbs too

I have them plumbed in and its never happened since

So unless you are using it only during summer months i would plumb them in, but you do get some nice dry sunny crisp winter days where you cant help but take it for a spin

[MikeB]

Small bit of progress.
I bought a susuki tl1000 LH silencer off ebay for £10. made up a link pipe.
Looks ok, its mainly to keep the neighbours happy, sound pretty good to.
May have to upgrade for IVA but fine for now. Will post a pic when I get her outside next.

So £10 for an exhaust not bad!

[MikeB]

Started to plumb in the cooling system.

Ordered the parts from ASH on ebay, good service.
1x 32mm 180 bend
1x 1m long pipe
1x 32mm joiner *may need one with a T-piece
1x 500mm length of 32mm hose, to be cut up and used as joiners.
1x 1m 16mm length of pipe

A polo radiator for less than £30!
and a push pull 12" fan from ebay, seems ok quality and powers up nicely


IMAG0362 by mjb22001, on Flickr

I'm reusing the sierra hose for the bottom rad pipe its not perfect but looks pretty good (not sure if this was the top or bottom hose on the sierra installation)
The pipe exiting the water pump was cut a re welded to make it shorter, I also welded it 180 deg so the small pipe exits downwards away from the manifold.

[MikeB]

I'll get some more pic ups tonight,
Progress, mounted the radiator, well at least the top mounts, I used rivnuts rather than welding the top mounts as I want to check the fit with a nose cone later one, once checked I'll weld on the bottom mounts.

Fixed my thermo housing by filing the ali away from around the snapped off steel pipe, got about 10mm clearance and using a cut off from an old coolant pipe with a flaired end I welded it on. Should work ok.

I've also started work on an alternator bracket. I've had to mount it the other side as the westfield exhaust manifold meant I needed to move the engine mount to where the orignal alternator bracket was.

I think I've got it to clear the carbs and the steering rack and I'm using the sierra alternator belt.

The good news is come post IVA zetec fitment everything is where it needs to be so it should be a easy swap.

[MikeB]

IMAG0368 by mjb22001, on Flickr

IMAG0366 by mjb22001, on Flickr

Just trying to wire up the alternator

Internet suggests this for the sierra alternator

B+ thick wire to battery
D+ to warning light
W is a 8 or 12v output for autochoke

[MikeB]

Tried it again last night with the middle post to the bulb,
Worked a treat, not sure why the wiring diagram in the haynes manual has it wrong! Bulb now goes out when the engine starts.
Ran out of cash for this month so it finishing jobs I have bits for. Mounting pedal box and front brake lines, fit rear ali panel, fit throttle cable. That should keep me going until the end of the month!