Thanks for asking!

Immediately after my last post, work got rather intense until the end of the year so I was not able to get things built as far as I wished. I did, however, spend time ordering parts and getting everything organized for success.

My first challenge was getting access to machine tools. In the past, I had access to legit machine shops at work. R&D has changed over the last 10 years and with the companies like Protolabs coming on to the scene, a lot of companies have eliminated their machine shops. I finally came to terms with needing to get my own machines. This precipitated a complete reimagining of my garage. I ended up getting a PM25 mill due to space constraints. This will more than adequately suit my needs and allow me to machine my throttle bodies and other custom parts.

My chassis parts came in. I ended up getting a DME swingarm. It's a beautiful piece and was worth the wait. If you buy a DME arm for your oil cooled, there's a few things to know. You have the option to choose between Gen 1 & Gen 2 Hayabusa rear wheel setups. Since I did not want to run an arm for the rear caliper and wanted to use the lighter Gen 2 rear wheel, I opted for the Gen 2. What I discovered since is that there's a chain line offset between the Gen 1 & Gen 2. The Gen 2 rear wheel has about a 3/8" further outboard offset vs Gen 1. Regardless of what you choose, both are different from the oil cooled chain line and will need addressing. I'll need a custom rear sprocket to fix it (not a fan of moving the front sprocket further outboard as this adds more stress to the outboard shaft). I also opted to switch over the the CBR 900 front wheel which is meaningfully smaller in diameter and lighter than the oil cooled front wheel. Pretty sure this front wheel will need some custom parts too to swap over.

My Hayabusa 3/4 turbo upper from Catalyst came in. This was the only option that I could find that had everything filled in.

My fuel injection swap over parts came in. I opted for the MAXXecu Race H2O ECU. They're a few consideration you need to keep in mind if you move to a MAXXecu. First is you need to convert over to a coil on plug setup. I opted to use Gen 2 Hayabusa coils as these are a very known quantity in the tuning world. You also need a timing module and I opted for the Bosch 0227100211 unit. This also requires a heat sink and got one off amazon (90x90x15mm). Additionally, you need a different ignition trigger sensor as the stock unit will not work. I used this one from MAXXecu (product ID 2012) which is known to work on the oil cooled GSXRs: Maxxecu sensor . I could not find anyone who would order the sensor for me with the exception of DME (you can't buy it directly from MAXX). They are pretty awesome to work with and can recommend them. There are also a bunch of connectors you need to wire everything together. There are several places to get them (ecuplus.de, carmo-electronics.com, ksvlooms.com, etc.). Got my injectors back from cleaning (Schnitz). There's more that needed for the swap but this is where I'm at.

I'm kind of at a Y in the road. I can choose to swap all of this over now (which will take some legit time) or I can just get the bike running now stock and swap over systems over time. I'm thinking I may just keep my chassis setup as is, run the motor stock with 40mm Mikunis, Sidewinder exhaust and traditional ECU. If I do the later, I will definitely have it done for the April 10th opening of New England Dragway. It will require more patience but will also be more fun as I get to see the improvements of each change on ET. This is looking like the direction I'll end up going for the start of the 2024 season.

 

Thanks for sharing your progress...I know it takes time and effort.
I've enjoyed following the build.

The reality of big projects...is they get completed in stages. We're often limited by time, out-sourcing, money etc.

Scott

 

I subscribe to the “don’t get it right, just get it running” mentality myself. There may be other unknown issues that you will need to sort out with your wheels/ suspension. Getting it on the track this season will probably be a lot more fun than working on it and you will undoubtedly identify issues that need to be changed by testing it

 

Would love an update on this project!

 

I’d like to see/hear any updates as well.
You mentions NE Dragway.. where are you located? I’m in S.Florida but growing up that was my track. I raced a Nighthawk S when I was 15.. 1987

 

Progress has been made on the build but it's been a bit like 2 steps forward and 1 step back. Part of the challenge is my builds are near the bottom of the list in terms of priority. I just have too many other things going on that need focus at the moment. Also, I'm playing the long game and approaching this with patience. There's lot that I want to achieve with my builds and it requires infrastructure to get put into place. For example, I want to be a competent engine builder and have capability to build my own chassis (with my own stuff - no interest in doing it professionally). Using an oil cooled as a platform requires me to be able to design fabricate my own parts. This requires infrastructure as well. And this is all great stuff. It's what I want to do. For me its more about the build than it is about the racing though that's important too. But this all takes time. Anyhow, on to the update:

I bought a full metrology setup with good engine building tools. Surface plate, full set of dial bore gages, valve spring tester, ring grinder, etc. I now have everything I need to fully inspect/blueprint parts, and assemble/disassemble engines. This took some time to figure out, acquire, and setup.

On the fuel injection front, I bought everything (I think) I need. There was a lot to figure out here. I'm running a total loss setup. The alternator was a 10lb savings! I needed to get a legit battery though to power all the electronics for a full day or racing. Got everything I needed fuel delivery wise. Using Fragola fittings and line, AEM fuel pump, regulator, and fuel filters. Figured out and purchased all the sensors I wanted. One thing I needed to figure out was the trigger wheel. I wanted to run a 24/2 trigger wheel so after much research, I designed and machined one. Also, I'm going to run Maxxecu's digital dash (MDash), which is what the tablet if for. There's other stuff I'm working on that's not pictured. I got most of my throttle bodies machined. Contrary to what you read on the internet, making 01/02 GSXR1000 throttle bodies fit is an involved process. Can be done but with much work. I'll be making a throttle body conversion thread in the future for anyone who wants to do the conversion with detailed analysis.

A bit back I cam across a new MTC big block with sleeves unmachined. I bought it and had it setup with 1371 pistons. Around the same time, I decided to have Cooper make me an all out cylinder head. It has all the tricks short of offset valve guides and splayed rockers. It's a 31 x 27.5 epoxy spigot head. Took me 9 months to get it back. Also sent my transmission to R&D to have him anneal the gears, and have the shift drum setup/machined. If you run a big shot of NOS, the bike isn't going to shift on the big end. That's what Brock learned back in the day. R&D figured out a solution for Brock and had my transmission setup the same way.

Yes, for the folks keeping track back home, this is the 3rd pivot I've made with respect to the body. I put together a pretty nice tiger stripe bodywork set. I decided in the end to make it look like a proper 92 1100.

And here's where the bike is at. Yup, this is also the 3rd pivot. I came to terms with the fact that if I wait to race until the fuel injection conversion is complete, it will be another year. I was going to pay to have Ryan Schnitz do it (the wiring) but he wouldn't return my calls. So I pulled everything off and put the carbs back on. It took me 3 years to find that sidewinder muffler (mine was toast). Got the 16" front wheel conversion almost done. It took 5 iterations of 3D printing to figure out the design for the caliper conversion. Still need to mill it up. DME swing arm is installed with a gen 2 bus rear wheel. I needed to fix the chain line back to what the 1100 had which took some time to sort out a solution for. Figured out what length of dog bone I needed to get the height set right and machined that up. Started the tinwork for the electronics. Need to reinstall the wire harness, fabricate a removable muffler baffle, machine the caliper mount, install the bodywork, and I'm off to the races. Will be done for this season. It will be slow (stock motor) but it will look nice and more importantly, will be at the track with it. Plan is to get everything in queue for the motor builds over the winter (I'll be doing 3 setups and dyno testing them all). That's where things are at. Slow progress but progress none the less.

 

Thanks for the update!
I admire your dedication and passion.