Tuesday, August 10, 2010

Race Report: St George Road Race Rnd 2 - RB Racing 4 Hour Relay

Overview:
This blog is the race report from the 4hr relay endurance race Rnd 2 St George Motorcycle road racing series. This race series is club series and GvD racing did not attend Rnd 1. GvD Racing joined fellow competitors to form a team of 4 riders. The race is a 4 hour endurance race, relay style, which means each rider uses his/her own motorbike for the race. There are numerous catergories and CTD Racing entered category 5: Senior, BEARS F2 or Any Group 3 - 5 M/Cycle, C & D grade.

The St George series is a relaxed motorbike race series at club level where riders can get together and have a bit of fun.

Date: 31st July - 1st August 2010
Track: Wakefield Park Raceway
Race Team: CTD Racing - Crash Test Dummies Racing

Rider / Bike:
Colin Lewis / Suzuki GSXR600 k7 / D Grade
Scott Gapps / Suzuki GSXR600 k7 / C Grade
Garry van Diggele / Suzuki GSXR600 k7 (k8 engine) / D Grade
Russel Downie / Yamaha FZR-600 1992 / D Grade

Spare Bike: Honda CBR 600 99

Race Report:
The race report is written from a perspective of Garry van Diggele

Sat Practice 1: Suzuki GSXR 600 k7
Track Condition: Wet but drying

After having purchased the engine, rebuild and installation finishing only in the morning of the 31st July 2010, the day of practice, GvD Racing was ready for testing. The team arrived at the race track exhausted after having an extremely busy week prepping the motorbike for the race meet. After sign-on, setting up and having a chat to the clerk of the coarse regarding getting a practice session in the team was ready to start. After finally finishing the bike by picking up and installing the brand new case protector for the engine we were ready to roll.

After having a quick chat regarding the track condition with team mates we hit the track very gently. We ran the bike on very low revs for the first 2 laps as well as investigating the condition of the track. There were 2 "rivers" running across the track at turn 2 and 9. Having the bike on slicks we were in for a very slow lap which was good for the gaskets etc anyway. After having a few soft laps with low revs we started to wind up the pace, 1st and 2nd gear felt great, quick shifter was working well and acceleration was strong.

In the fast sections 3rd gear felt a little sluggish but we were still taking it easy. In the 3rd lap after picking up the pace significantly we noticed that 3rd, 4th and 5th gear were very weak. It felt extremely sluggish with slow response, fluffy and significantly struggled to rev past 12K revs. We were unable to get the bike above 14K revs and were not even able to get the bike into 6th gear on the straight. After pulling into the pits and taking the bike apart we made a small change. We noticed the bike was running extremely rich so the small change incorporated attaching another breather tube from the throttle tube which we originally blocked.

Sunday Practice 1: Suzuki GSXR 600 k7
Track Condition: cold, damp but drying
Rider: Scott Gapps
Fastest Lap: 1:14.09

After making changes to the intake of air for the throttle body, Scott Gapps went out to test and run the engine in. One lap and it was determined that the Suzuki needed to be retired for the race meet. The bike was still running fluffy and rich. Scott continued the session with his race bike putting consistent laps on the board.

Scott ended up having the fastest laps for the class CTD Racing is competing in.

Sunday Practice 2: Yamaha FZR 600 '92
Track Condition: cold, damp but drying
Rider: Russel Downie
Fastest Lap: 1:15.108

Russel was the next one out on hit hot fire-engine red Honda. The track had dried quite a bit was still tricky with damp conditions. Russel completed his practice and felt comfortable on the track having consistent results.

Sunday Practice 3 / Qualifying: Suzuki GSXR600 k7
Track Condition: warm and dry
Rider: Colin Lewis
Fastest Lap: 1:08.162

Colin was selected to complete the qualifier for our team. Colin had completed the previous day's practice and was confident of being able to achieve a good results. As it was an endurance race our strategy was to ensure we had a decent start but consistency is more important than fast times. Colin went out and was able to qualify 19th out of 40 entrants. We qualified 6th for our class.

Sunday Practice 4: Honda CBR 600 '99
Track Condition: warm, windy and dry
Rider: Garry van Diggele
Fastest Lap: 1:10.884

As Garry had to retire his bike for the event he hit the race track on a bike which he had never ridden before, the spare Honda. The Honda was setup with road pattern for gears and suspension for a 60Kg person. The Honda is also a carby and 10 yrs old. As Garry hit the track there were many concerns due to the huge number of changes compared to his race bikes which are EFI, setup correctly and race pattern gears. Anyway, after a few careful laps Garry picked up the pace. The gear changes became smoother with the selection going right more often. Garry was quickly reeling in his competitors and managed to decrease his lap times every lap. At the end of the session with the revised riding style Garry managed to be the 3rd quickest of the riders in his class.

Quote
"Coming into the corners the first few laps the front would wobble significantly. Normally i push the front very hard into the corner and use the rear to steer out of it. With this bike I had to adopt my corners significantly. Weight had to be right back, back in the bike, power on the gas and slide the rear out significantly to keep as much weight of the front as possible"

"Awesome bike, it feels like steering a big boat around the corners... A few scary mistakes coming into corners with gear selections but a solid first outing. This bike is quick and if we sort out the front we should be able to lap consistently in the 9's."

Race:
Starter: Colin Lewis

After a brief discussion it was decided the best person to start the race was Colin Lewis. It is important to get away cleanly with 40 competitors on the track. Colin is also a very aggressive rider especially in the first few laps when things are very tight. Colin had a strong session and when it was time to pit we were running in 10th position. Russel was the second rider and again we had a solid run. The first hour went very quickly without any incidents and we were in a strong position. It was decided to do approximately 30 minute sessions each.

Garry was the next rider out and with only 1 practice session on the bike significant setup changes were made. The pre-load on the  bike was increased significantly (to the maximum) and other adjustments were made. Garry went out on the track and the changes made big improvements. Lap times were consistently faster than practice and with a lot of people on the track positions were increased. after about 10 laps a problem was noticed, under heavy braking, liquid flew up all around the front of the bike and onto the windscreen. Garry quickly pulled into the pits thinking a burst radiator. Scott was the next rider out and the team investigated the bike. It was determined the liquid was petrol and it was everywhere at the front of the bike. No where near the breather or overflow tubes. After pulling the bike apart it could not be determined the source of the spillage.

Scott finished his session and Colin went out next. Both Scott's and Colin's sessions were strong with no drama's. The team was in a very strong position and were just informed of severe weather warnings for the afternoon. It was estimated the weather would come in the next 60 minutes. It was decided to send Garry out again as we could not determine the source of petrol. We believed it was potential overflow from the cap and was not considered a major issue, however, if it continued we would retire the bike.

Garry was able to put up consistent fast laps and was lapping a lot of people as fatigue set in for most riders.

Quote
"There was one section, corner 4 and 5, a very tight section where you would be lucky to fit 2 bikes next to each other. I came up to a group of 4 riders quickly and made a move on the outside. I believed it was a little tight to make the move on all of them and was next to one rider waiting my turn. Out of nowhere a R1 came on the outside of me leaning on my bike, i was consequently on the bike next to me and he shot past almost taking out the 3 riders in front. A gap opened up and I followed in his wake overtaking in the fast corner 6. It was incredible tight the track with so many riders and mayhem, it was an unbelievable experience."

Mayhem broke loose as the weather came early. It started to rain and 7 bikes went down, yellow flags came up. As Garry approached a group of riders the flags were raised. Mid corner they stood the bikes up (reaction to flags raising and overtaking rules) and Garry had to use his front brakes middle of the corner in wet weather to not take them out from behind. Obviously, next thing, Garry was sliding down the road, holding the bars into the mud pool next to the track. He was quickly up and hit the track again pulling into the pits. As the bike was considered safe Garry was send out again and joined the riders behind the safety car. In the mayhem of the heaven's opening up 2 riders had collected each other and the safety car was out. The tyres were changed for Colin's bike and Garry got called in to pit. In the next 10 minutes we lost many positions making some bad calls regarding strategy. The heavens closed and the track was dry, Colin came in and Scott went out again followed by Russel. The heavens played havoc with our strategy and again it started to rain. Colin went out again and finished the race. We were very strong in the wet weather with very fast times considering the huge down poor. Unfortunately due to the weather playing havoc we lost many positions. We ended up finishing 26th, in total CTD racing was happy with the results with the blokes having a great time. This race was for all of us to go out and have some fun. We weren't necessarily concerned with results and lap times as none of us had competed in the first round.

The weekend was great fun with drinks Saturday night, motorbike racing Sunday and having a safe weekend with not to many incidents. CTD racing finished 6th in the class which was disappointing but for the first ever endurance race for 50% of the team including GvD racing it was a very valuable experience.

Monday, August 2, 2010

Suzuki GSXR 600 07 / 08 Engine Swapout part 1

Overview
This blog post will cover an Engine Swap from a Suzuki GSXR 600 k7 to a Suzuki GSXR 600 k8 engine. The reason for the engine swap is that the 07 super sport engine broke a shaft whilst racing in Race 2 Formula Extreme formula Oz class round 3.

Initially the engine was going to be replaced by a k7 engine, however, upon investigation the k8 uses the same engine mount positions. Initial research suggested it would be a straight forward swap as the Yoshimura race harness and ems pro is the same for the k8 and k7. We also ensured that in-case the mounting was different we got the k8 wiring harness, stock ecu, and dash.

Difficulty:
High - changes require include dropping the engine, wiring harness etc. It is recommended that you have a-lot of experience with motorbike repairs and comfortable replacing parts. Anything you are unsure of check the service manual and take photos for any plugs and sensor connections your not sure off.

Disclaimer:
All changes, views are correct at the time of writing to the best of knowledge of the author. These parts are for Australian Motorcycles and it may differ at your location. You are responsible for any changes made to your bike and if you decide to try this check everything with your local dealer and service rep.

Differences
After purchasing a complete engine kit (engine, wiring harness, etc) the following differences were observed between the k7 and k8:
  1. Intakes
  2. Throttle bodies
  3. Injectors
  4. Throttle body - fuel clips
  5. petrol pump
  6. Direction of the fuel connector (makes connection to petrol tank very difficult)
  7. ECU system (kill switch block), 3 map settings
  8. Dash, for the maps, mounts the same as the k7
  9. Higher compression engine
  10. Different engine internals
  11. Different thread for the idle screw, Yoshimura k7 idle adjuster does not fit
Some of the k7 Yoshimura parts are re-usable, they have not been used for this engine as we are keeping the engine in superstock condition instead of supersport. Speak to your engine builder before purchasing any parts.

Photos of the K7 throttle body


Photos of the K8 throttle body


Upon further investigation there have been major changes to the throttle body and head. There is an additional air tube which goes to the k8 air-box (we are currently using a k7 air-box).
Installation
Please note we are using a Yoshimura race harness which is NOT the same as the k7 wiring harness. It only has the essential sensors and plus required to make the engine and dash run correctly (Suzuki error codes still work).
  1. Remove the k7 engine, radiator, air-box, petrol tank, ensure you label/note all the plugs and sensors.
  2. Remove the wiring harness if you are using stock harness
  3. Remove Dash
  4. Install the engine (make sure the throttle body is off it), easiest if you do the back bottom bolt first, then do the back top bolt. Tighten the engine bolts to the required torque setting in the service manual.
  5. install the wiring harness positioning everything in the same position. be extremely careful to ensure that you place all the sensors the correct way, especially the tip over sensor (if you get an FI light its most likely a sensor issue).
  6. Attach the petrol tank, you will need to ensure your fuel line reaches both without over stretching. The 08 uses a different blue clip to attach which will not fit the hose. Modify to fit.
  7. Bike should start, any error codes check your plugs especially sensors. We had to cut some plugs to ensure they fit.
  8. Once everything is installed ensure you bleed both the water and the oil in the head. Make sure you have the correct amount of oil. Start with adding 2700 ml (should always change oil filter). Leave the bike running until hot. Switch off bike and leave it for 3 minutes, check the oil level.
  9. Ensure that the water pumped through the engine and is bled properly.
  10. slowly run the engine in, if feasible test the bike slowly on closed roads. If changing the wiring harness to the 08 everything should be ok and no tune will be required (if everything is stock). If you are using the yoshi EMS system, or the 07 harness (should be possible) you will need to tune the ECU and/or buy something like a PC5, bazzaz efi controller.
Testing - 31st July 2010 / 1st August 2010
After the rushed engine swap and rebuild (1 week including pickup 1000km away) the only test to safely test was at the next race meet which was a 4 hour endurance race. The perfect test. The bike was tested in 1st and 2nd gear before the trek to the meet.

After arriving, setting up and sign-on the bike was taken out into the first practice session. The first few laps were done very slowly with the bike responsive in low gears 1st and 2nd. The bike felt a little sluggish in 3rd gear but as we were not pushing the revs it was simply considered running in. After a few laps the pace quickened and it was soon discovered the bike refused to accelerate past 14K revs (red-line is 16.5K). The bike felt extremely sluggish and slow in 3rd, 4th etc. The bike also felt very unresponsive, upon inspection it is running extremely rich. After calling the Suzuki Factory Race Team it most likely needs a tune. Unfortunately they are the only ones in Australia capable of tuning the bike (1000 km away), as such, the bike is currently not running correctly. The bike had to be retired for the race meet and we ended up using a Honda 99 cbr 600 carby with very soft suspension for the race meet.

Upon investigation and a few phone calls and mechanics we believe it is the mapping as the injectors are different. The bike is currently scheduled in for a tune by the Suzuki race team. An update will be provided with the results including Dyno results. We will also update the results with the new engine from race meets. We will also do an analysis about the benefits of the 08 model.