Round the Bend

We have a problem...
The motorcycle throttle body is cable operated and the SU carbs were operated by a lever setup that would make Rube Goldberg proud.

Q: How to make a lever operate a cable? It turns out Dad is full of good ideas, and screen door parts.

spark and start

We added a wasted spark ignition control circuit to the megasquirt using a ford EDIS coil pack. Now we have a beautiful spark and a running engine. We used the ISL9V modules soldered to a bread board inside the megasquirt and added 9-pin connector for the wiring.

Next on the agenda is to fix the electric cooling fans (still the old Lucas electrics) and get tuning.

New billet aluminum intake manifold (no more Leaks!)

First Breaths

The throttle bodies and fuel rail mounted onto the car.

The air intake temperature sensor for the megasquirt is hidden into the back of the K&N air filter.

All of the fuel injection parts. 

After getting a brilliant spark from the Ford EDIS6 module, once we hooked it all up to the megasquirt, there was spark no more. Fortunately we remembered how it was done in the old days, and grabbed the distributor and coil off the shelf. After Re-installing the distributor The car actually started!!!! Although it ran poorly.

Stay tuned Next on the agenda is wiring up the LC-1 Wideband oxygen sensor and starting to tune the megasquirt, but this may have to wait for warmer weather.

EDIS Woes

The original idea for the ignition system was to use a Ford coil-pack and EDIS module.


The megasquirt manual has a great write-up on EDIS if you don't know what it is.
http://www.megamanual.com/ms2/EDIS.htm


The necessary parts were procured on eBay about 3-years ago at the start of the project, and have been collecting dust ever since.

An aluminum spacer provides a convenient location to bolt the trigger wheel onto the existing damper and space it far enough away so that the VR-sensor wont interfere with the alternator belt or pulley.

We fabricated an aluminum bracket to hold the VR pickup at 60 degrees before the missing tooth (at top dead center) as required for "limp mode" of the Ford ignition. The VR sensor bracket mounts to the alternator bracket, with a stabilizing arm that connects to one of the timing cover bolts to help keep it rigid.

EDIS bracket and alignment (before re-installing the radiator)

Another shot from the top, shows the alignment and attachment below the alternator.

Ray Livingston also has a very nice looking setup for the megajolt which I was seriously considering, but I had already done most of the fabrication work by the time I came across this http://etypeuk.com/forum/viewtopic.php?t=437


We got the coil pack and EDIS module wired and sparking beautifully in "limp mode" even with the engine cranking over at very low rpm (<100). Unfortunately when we hooked it up to the mega-squirt the spark went away.

Nothing appeared to be visually damaged inside the EDIS module when we opened it up.
Although we did learn that it is potted in an odd jelly like substance.

A week later Autozone confirmed the EDIS6 module was working when they bench tested it.... At any rate we had already moved on.

Mounting the coolant rail.

Here is a nice picture of the intake manifold and coolant rail bolted to the engine.

Amazingly the manifold bolted right onto the car. 

We are re-using the XJ6 coolant rail, which was nicely re-painted black. This way we can keep the thermostat housing and return lines in close to the original locations.

  
 Here is a nice shot of the intake, without the throttle bodies installed yet.

 It wouldn't be British if it didn't leak.

 A quick pressure test of the system revealed our first major hurdle. The bolt holes which were still open to the water passage were unfortunately also open to the edge of the runners. Hence we have a pretty bad coolant leak. On the positive side, it wasn't leaking coolant into the intake.

Re-spacing the ITBs

Today I had a few minutes to turn down the spacers for the throttle bodies on a lathe.
The three pairs each had to come closer by 150/1000 of an inch. from 3.15 to 3 inch spacing.

going from 1998 GSXR-750 Throttles

to this

to mounted with rubber insulators