This post will cover the second part of the engine swap-out. It will specifically cover the problems diagnosed at the last test session.
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.
Additional Work:
The bike was sent down to Phill Taiton Racing, the Australian Suzuki Factory race-team for diagnosis and an engine tune. It was initially believed that the problem was the engine map of the Yoshi EM Pro harness and ECU. After a good day investigation and a few dyno runs it was found that the problem was dirty injectors. The injectors were changed to the 07 injectors and it was put on the dyno. Dyno graphs will be made available at a later date.
Phill from PTR also went over the bike to make sure everything was ok. As requested they revalved the Ohlins TTX rear shock and put a new spring on. The spring was changed from 110 Nm to 100 Nm. The ride height was adjusted for Phillip Island.
After successfully tuning the bike and having a rain and dry map the bike went to Phillip Island Grand Prix Circuit for testing.
Suspension Note:
Phill when he inspected the unit said there was something majorly wrong with it. This was odd as I had the unit serviced including revalving done recently by Teknic a suspension specialist in Australia. Anyway, he said it felt like there was air in it. He also put the shock on the dyno to get a before and after picture. He confirmed that there was no damping for slow velocity and that's why I have been having rear end trouble. After opening it up he noticed that they used the wrong oil for Ohlin's, there was air in it and was put together wrongly! This is a huge mistake by the shop and I will never use them again. Phill fixed it all up and put a new spring on. Dyno results will be put on at the bottom of the page when I have scanned them in.
Suspension Note:
Phill when he inspected the unit said there was something majorly wrong with it. This was odd as I had the unit serviced including revalving done recently by Teknic a suspension specialist in Australia. Anyway, he said it felt like there was air in it. He also put the shock on the dyno to get a before and after picture. He confirmed that there was no damping for slow velocity and that's why I have been having rear end trouble. After opening it up he noticed that they used the wrong oil for Ohlin's, there was air in it and was put together wrongly! This is a huge mistake by the shop and I will never use them again. Phill fixed it all up and put a new spring on. Dyno results will be put on at the bottom of the page when I have scanned them in.
Testing:
It was the first time GvD racing went to Phillip Island Grand Circuit and with a newly tuned bike, it would be an interesting day. It was decided to do the testing with the Suzuki Race Team because if any issues were found we would be able to solve them straight away. It was identified in the first session that the bike felt very different. The bike felt very stable on the super smooth track and even under braking, the rear would not step out.
On hard acceleration around 14K revs the bike would lack a little power and suddenly kick off. After having a chat with Phill after the first session it was deemed that the bike was running a little lean. His team was having the same problem and he offered to change it. However, as the day was warming up significantly we decided to try one more session with the current map. The sprockets were changed to a better ratio and with warmer temperature the problem went away. We also raised the PSI of the tyres as they were getting very high wear on the super fast track.
Further sessions it was noticed that the suspension felt very hard but with a lot of traction. The stroke felt very smooth and linear unlike before. It was noticed that rear grip had significantly increased and we could get on the gas a lot earlier. The bike was very stable on hard braking with the back end not stepping out, this was a significant change to previous handling of the bike where the rear would easily slide under braking coming into corners.
In total all the work was well worth it. The k8 engine works very well in the frame and the exhaust system fits works well. We have a peak power of 124Hp with very linear power delivery. The suspension feels very strong and the geometry extremely stable under speed. The rear will be raised for tighter tracks like Wakefield as Phillip Island is very fast and flowing just like Eastern Creek.
I would recommend this upgrade if a new engine is required. If you get a complete engine kit it should just be a matter of changing over the wiring harness and K8 ECU. Your 06/07 exhaust system should fit and I recommend you use that as the catalac converter is in the muffler and the system is more free flowing.
Further sessions it was noticed that the suspension felt very hard but with a lot of traction. The stroke felt very smooth and linear unlike before. It was noticed that rear grip had significantly increased and we could get on the gas a lot earlier. The bike was very stable on hard braking with the back end not stepping out, this was a significant change to previous handling of the bike where the rear would easily slide under braking coming into corners.
In total all the work was well worth it. The k8 engine works very well in the frame and the exhaust system fits works well. We have a peak power of 124Hp with very linear power delivery. The suspension feels very strong and the geometry extremely stable under speed. The rear will be raised for tighter tracks like Wakefield as Phillip Island is very fast and flowing just like Eastern Creek.
I would recommend this upgrade if a new engine is required. If you get a complete engine kit it should just be a matter of changing over the wiring harness and K8 ECU. Your 06/07 exhaust system should fit and I recommend you use that as the catalac converter is in the muffler and the system is more free flowing.
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