830cc experience?

[1Fast7]

Has anyone done this conversion? I just bought zx9 pistons and cylinders and would like to do it. I hear that i can get 160hp out of it. I would like to know its street manners. I have done a lot of searching but i can't find anyone that has done it personally . There was a site zx8r.com but it is no longer up and running. Besides it was mostly on the newer 96^ 7s'.

[NINJARDR91750]

That Link You Posted On Another Thread Said That Boring The Cylinders Out That Much Would Cause The Cylinder Wall Closest To The Motor Mount To Be Unstable/to Thin. You Might Check For Yourself Thou?!

[ridn92zx-7]

you would want to sleeve the cyclinder walls to prevent that. it can be done for a pretty penny. i have never done this but i do know on cars you usually want to sleeve the walls or have them redone with carbide. a shop around here in cincy does is and are nationally reconized for their work. like i said i have never done it so i am just giving my worthless two cents good luck and keep us posted.

[DaveMK2]

My $.02
Yes you might reach 830cc's by re-sleaving and dropping bigger cans in there. But you probly wont see the HP you think your going to see. Alot more work goes into creating horsepower than just dropping in new pistons. You also need to think about cylender head/valve clearance(deck height) when putting different pistons in.

I know in the car racing world you can figure that for 1 HP youll end up by spending $100.

As the old saying goes,
"Speed costs money, how fast you wanna go?"

Best of luck with your project. I would love to see some pictures of your work in progress.

[1Fast7]

I have read that you heat up the cylinders so the sleeves come out. The you bore out the area were the old sleeves were so that the zx9 sleeve will fit in there. the you have them milled down to the same height as the zx7 sleeves. The zx9 sleeves are about 10mm taller. It takes it from 72mm bore to a 75mm bore. Then you use zx9 pistons. You don't have to do any thing special to them as they will mount to the rods (same pin size). I heard that 150-160hp is not unrealistic with the supporting mods and tune of course. That is were the fuel injection comes in I'll be able to tune it better than with carbs. I was hoping to find someone that has done it. I would like to know what its street manners are like? How hot it runs in traffic and how fast of a throttle response it has? But first i have to get the ecu programed and running.

Picture of the bike. It has a bit more work done to it since this picture.
http://i157.photobucket.com/albums/t...T/DSCF0222.jpg
The zx7 carbs compared to the zx6r throttle bodies.
http://i157.photobucket.com/albums/t...T/DSCF0625.jpg
Throttle bodies on the bike.
http://i157.photobucket.com/albums/t...T/DSCF0619.jpg
http://i157.photobucket.com/albums/t...T/DSCF0617.jpg

[Kawi_T]

My ZX12 dynos at 165 so I have a hard time believing that an 830 can equal that. Also, you guys talk about the bottom end, but really I don't think thats where any of the HP is coming from. I think all the modern improvements are in the head. The bottom end is the same as it always has been. Alright, we have coated cylinders and lighter parts and other small improvements, but any major gains are in the head. If you want HP look to the head. Bigger cams, better valve jobs, better springs, whatever. The HP is in the head.
T

[1Fast7]

I am going to get some different cams. I may also go with a velocity port job. That is still in the air though. I am setting this up so that i can turbocharger it later down the road. The intake manifold is set up to with stand the boost already so all i have to do is add turbo.

165hp seems a little low from some of the other sites i've been at. I read somewhere that the zx12 dynos at 167hp stock. With bolt ons and a commander they were at 190+. So if i can hit 150 i'll be happy.

[hessdawg]

wow somebody else is gonna fuel inject there bike
i've been researching this for a few weeks now. i have so many questions for you.
what are you using for ecu?
are you gonna control the spark too?
do the 636 TBs fit your stock air cleaner?
does your throttle cable reach?
how much fuel pressure are you running?
what fuel pump are you running?
do you think our stock 30 amp alt will handle it?
I'm sure i'll have more for you later
thanks brad

[oldgreenmachinetwo]

if all you have to do to get the sleeve out is heat it up, why doesn't it fall out during normal operation? and yeah, that sounds like testosterone talking on the hp numbers.

sounds like your sinking a lot of money into an old 7, which i personally think is awesome.

[1Fast7]

They would fall out if they didn't have a lip around the top of them. A sleeve is no straight. As for horsepower i see tuned 765s' and 793s' putting out 143hp to 150hp. So a 835 should put out at least 150.

The ecu is a microsquirt it will control the fuel and timing. You can google megasquirt or microsquirt for info on it. I don't know if it will fit the air box as i have plans to turbocharge it later so i have made my intake out of aluminum.

The cables will fit. The choke will fit with some modifications. If i remember the little aluminum piece that you slip in the slot at the throttle bodies is a little larger than the hole. So i went to the local hobby store and found something that works. I didn't like how the 7 cables were so i used the 6 cables and a 10s' throttle tube.

The fuel pump is from a 05 6. I had to cut and weld a recessed cup under the tank to get it to fit. The pressure is stock @ 30 some psi. The 30a fuse is the same .

[oldgreenmachinetwo]

so the injector is shooting at 30 psi? isn't that low? i'm still new to fuel injection but i thought f.i. shoot at 1000's for diesels and still in the 300-600 psi range for gas engines. i think the turbo is cool and stuff, but i think it's way cooler your switching a carbed bike to f.i.. that's too god damn cool. seriously. durbahn switches rc30's and i think he did an old 7 "back in the day". he might know a little something.

how expensive is mega/microsquirt? where are you doing your machining? are these your tools or what?! good luck!

[1Fast7]

Fuel injectors start at around 20 some pounds per injector. The largest injector is somewhere in the 160lb range each. Most auto manufactures run in the 30lb range.

The ecu is not that pricey i got mine for $425. Now they are not plug-n-play you have to program it to you engine and tune from there. That dose not include thing like throttle position sensor, air temp sensor, map sensor, 02 sensor and what ever else you'll need. Now you can get them for less if you know how to solder good. You can buy them in a kit form and put it together yourself. There is a forum for support for all you need to know also. http://www.microsquirt.info/ and http://www.megasquirt.info/

[hessdawg]

most bike efi runs on 3 bar which is 43.5 psi.
diesels do run on on much higher pressure in the hundred thousand range.
i have been looking at the gsxr and honda TBs cause they have the built in electronic secondary valves for choke. i was gonna do the micro but it doesn't have the onboard stepper motor controls for that. I'm not sure is you can add that though? ANd i was also gonna do an in tank pump but all the other tanks are steel and mine is aluminum.
and now for the questions
when are we gonna see some pics?
what turbos are you looking at?
what are you gonna use for crank trigger?
are you using the stock coils?
thanks again
brad

[oldgreenmachinetwo]

hmm... i must be thinking of something other than psi then... ? I'll go check it out. I looked at the cylinder liners from my old 9 and realized what you where talking about. they're all so close together it's impossible for them to move anyway. yeah, switching to fi is pretty damn technically demanding. it seems like LOTS of knowledge and LOTS of very expensive tools would be required. definitely keep us updated! and good luck!

[hessdawg]

I think is waaaaayyyyy easier and more logical than dealing with carbs.
the only tools you need are a computer and soldering gun.
all the knowledge come from other guys on the forums.

[NINJARDR91750]

Most Diesel Trucks/ The Cummins 2 Gen 24 Valve Runs 2 Fuel Pumps In Order To Build The Fuel Pressure Needed To Run Correctly With The Stock Turbo. 15 Lbs. Of Boost Is Around Norm For A Factor Set Cummins But Adjusting The Waste Gate Can Add 5-6 Lbs. Of Boost.

[hessdawg]

those pumps are like $1500 too

any pics yet???????
or you can email them to me and i'll post them

[1Fast7]

No pics yet. I probably wont have work done to for a few weeks.

[crazy_zx795]

Sounds friggin awesome. I'd love to see that thing turboed and then put on a dyno. Can't wait to see the results of ur hard work.

[cgifly2]

Sounds good always with someone elses money!