KZEFI 810 Turbo E85 Build

Ive been working on this for a while and finally posted this because Kawasakik1e brought the megasquirt a KZ thread back to life.

Specs:

1980 KZ 750 H1 motor. Hyvo timing chain
-810cc
-ported and flow benched. 68 cfm at 10" and .3" lift on stock cams.
-Stock cams
-ARP head studs
-ARP valve springs
-Neway valve job (Ground keepers, retainers and valve stems... it got messy :S )
-APE clutch
-Zr750 oil pressure regulator
-oil thermostat/ 10AN oil cooler ( goes between rear M18x1.5 oil port and main galley. oil pan galley blocked off half way through)

EFI Conversion
-LS2 Square truck coils (D581, 12558693)
-Using the stock VR sensor with the advancer locked in place for a crank sensor
-Welded a bung to the valve cover above a cam lobe for a hall effect sensor.

-Siemens a2c59514053 / 1439800 fuel injectors. 240cc. I will be running these at 55psi base pressure. I specifically choose these because they squirt at an angle, so the fuel will hit the back of the valve and not the bottom of the port like the stock gpz injectors!
-Bosch 69238 Fuel pump. Smallest i could find. Using a returnless fuel system with a Ford fuel pressure sensor and madhu controller
-GM flex fuel sensor

-GM 3 bar map
-GM CTS w/ bung welded into oil pan. Using oil as coolant temp sensor
-GM IAT
-GSXR Mikuni TPS
-GPZ1100 Throttle bodies
-KZ750 carb boots (dont use the 16065-1135 boots, both have to be ported for the GPZ throttle bodies!)
- MicroRusEFI ECU

Turbo
-TD02.5 Mitsubishi turbo should be able to do 120+HP. if not ill go to a Volvo turbo from one of their biturbo V8s
-M18x1.5 to 4an banjo for oil feed of off main galley.
-Hoping to mount turbo high enough to not need a scavenge pump.

Hoping to have first startup in a few days, I've been looking for a new frame for it though, so no rides unless i take the 650 motor out of my 550.

You know the rules... photos or it didn't happen.

Can't wait to see it.

loudhvx wrote: You know the rules... photos or it didn't happen.

Can't wait to see it.

Exactly. I have a Honda 50 mini bike with 2 blown and injected Corvette 454 engines in it, and it turns the quarter mile in 1.3 seconds. Oh wait, did I forget to post photos? :laugh: :laugh: :laugh: :laugh: Ed

Yes! I'm all in.... following. What specifically is your setup for ignition(trigger wheel, etc.)? Can we see a pic or schematic of vr sensor. Sounds awesome!Thanks In Advance .

650ed wrote:

loudhvx wrote: You know the rules... photos or it didn't happen.

Can't wait to see it.

Exactly. I have a Honda 50 mini bike with 2 blown and injected Corvette 454 engines in it, and it turns the quarter mile in 1.3 seconds. Oh wait, did I forget to post photos? :laugh: :laugh: :laugh: :laugh: Ed

I am trying! the forum is crashing when i upload photos.

Kawasakik1e wrote: Yes! I'm all in.... following. What specifically is your setup for ignition(trigger wheel, etc.)? Can we see a pic or schematic of vr sensor. Sounds awesome!Thanks In Advance .

You'll see when i get these pic uploaded

Stock ports:


Current ports:


APE parts:


TB rack:


Side profile of rack w/ injector


Nozzle end of injector


Modifying the TB rack shaft for the mikuni TPS. Not a direct fit on the shaft as the 750turbo forum said.



CAD model of TBs. I need to redesign and fab the fuel rail and TPS mount because :sick:


Doing valve shims. I was really close here. Largest shim was 310, smallest 290.


Locking the stock advancer. used a M2.5 (or #3 standard bolt is perfect too) in a pre existing hole in the advancer,


Oil cooler and turbo fittings


mid way through the clutch rebuild. I meant to get the solid GPZ dampers, but i guess that's the difference between the kz750 and gpz dampers. oh well. my fault


Hole in valve cover for hall effect sensor


Bung welded on:


Current state:

Nice!
That looks like a handful.

In case it comes up and you need it, here's an approximated model of the VR signal.
Some pickups have slightly higher amplitude than others, so the amplitude values are rough approximations.
s3.amazonaws.com/gpzweb/Ignition/KzRelucSignalApprox_copy.GIF

That looks great....! I will be following any updates! I just got home from some running and my Gpz1100 TBS AND my MS2 were on my doorstep. I've got about 6 weeks of home improvements I'm working on right now... but getting a lot of research and parts ordering going. This is something I've been slowly looking into for about 5 years and just recently pulled the trigger on going the fuel injection route. Plan on starting by getting the stock 650 EFI'ed - that will be a bit of a learning curve.
I have a 750 motor that will be completely disassembled and have a jug bored for 810cc kit I have on hand, I have turbo on hand.... that will be my turbo motor build.
Currently close to finishing a KZ1000 that is punched out to 1105cc with high lift cams. I've blasted and powder coated that one... going to be real sharp.... but that's another subject!
Thanks for the awesome pics! I'll study them this evening !

Got a chance to review your post on detail. VERY nice! Lots of good details.in there.....
Where did you get the Bung for your Hall Effect Sensor?

Sorry for the delay, didnt get a post notification.

Got a chance to review your post on detail. VERY nice! Lots of good details.in there.....
Where did you get the Bung for your Hall Effect Sensor?

I machined that at work

That looks great....! I will be following any updates! I just got home from some running and my Gpz1100 TBS AND my MS2 were on my doorstep. I've got about 6 weeks of home improvements I'm working on right now... but getting a lot of research and parts ordering going. This is something I've been slowly looking into for about 5 years and just recently pulled the trigger on going the fuel injection route. Plan on starting by getting the stock 650 EFI'ed - that will be a bit of a learning curve.
I have a 750 motor that will be completely disassembled and have a jug bored for 810cc kit I have on hand, I have turbo on hand.... that will be my turbo motor build.
Currently close to finishing a KZ1000 that is punched out to 1105cc with high lift cams. I've blasted and powder coated that one... going to be real sharp.... but that's another subject!
Thanks for the awesome pics! I'll study them this evening !

that sounds awesome man! i focused on getting it running first and then will go back for paint. I cleaned all the parts before assembly, so another clean and masking and it will be ready for paint.

As for EFI parts and tips...
Ive bought parts from ballenger motorsports (tools connectors, sensors), ebay (genuine sensors, connectors, wire assortments) and amazon.

Do not cheap out on connectors, wire, or sensors, well anything really! haha

I would recommend buying connectors with pins (no pigtail) and making the harness way cleaner. When you do need to branch or butt a connection, use barrel crimps and put a solder heatshrink thing over it

I'd recommend TXL type wire of the proper gauge for your ecu/connectors/amperage.

Make sure you get a good crimper for every kind of terminal/crimp you have.

Dont use those stupid waterproof marine crimps (metal is too soft and wires pull out so easily). use standard insulated or non insulated crimps.

use shielded cable for the VR sensors, especially if they are near the spark plugs. i stole some from the O2 sensors from a car harness

Finished up the harness! Well, the boost solenoid and flex fuel sensor arent wired in yet but everything else is.

Following!