Turbo solenoid help please

1433 Views 17 Replies 8 Participants Last post by RoadManiac, Dec 21, 2016

KAUAIHD

Discussion Starter · Dec 2, 2016

4

Hello there guys,

I have here a 2007 GSXR 1000. It's got what I can only assume is a homemade turbo kit on it, the turbo is internally gated and I can't seem to find a kit that comes with an internally gated turbo. The original wiring and everything is just insane whoever installed it I really don't know what they were thinking on it. Anyways, I need a bit of help with the turbo vacuum solenoids, there are three solenoids in the turbo system here, and I just can't figure out what on Earth you would need three for. If anyone could give me some hints on what these are and where they should be wired to that would be a great help. Thank you!

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oldgixxer

· #2 · Dec 3, 2016 (Edited)

Thats a rats nest of wiring you have there. Seeing that there is a small bung welded to the cold-side charge tube I would guess its for a water injection system.
Also could be some sort of boost controller. My AMS-1000 has 2 solenoids,but they look nothing like what you have. Doubtful its a boost controller,especially with an internal WG

What was the sellers description of what all is included when you purchased it(assuming thats how you obtained it)??

Also,get rid of that internal gate,it will boost creep and possibly melt expensive parts.

You have any better pics of everything that came with the turbo?
@Maj750 or @HeJason

HeJason

· #3 · Dec 3, 2016

Need some pics of the turbo, and plenum. Is it intercooled? Solenoid does go into the up pipe before the plenum, so probably not intercooled if that is a water injection line. Water injection should be after the intercooler. We need more pics to really see whats going on. Pics of the turbo hot and cold side would be helpfull. :cheers

Reactions: 1

FMJ

· #4 · Dec 4, 2016

Looks like a pressure switch probably to activate that water injection set-up, and second looks like pump,third soloenid to open under boos to let water injection work.

Reactions: 1

oldgixxer

· #5 · Dec 4, 2016

Need more pics of the entire turbo setup

KAUAIHD

Discussion Starter · #6 · Dec 6, 2016

5

Hey guys! Sorry for the snail response. Thank you for your input thusfar, I never even thought of water injection, I'm not familiar with water injection my self, but that would make sense. Yeah I got a great deal on the bike, I traded him a couple of ferrets actually. Of course the bike is a mess but... ferrets.
The bike will run. The turbo doesn't have any play or anything and seems to be in good shape.
So I guess my question at this point would be, if this is all components of a water injection system then I could just delete all these pieces and run the turbo as is?

I've got some more pictures here to post but I have to do it on another post due to the size of the images.

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KAUAIHD

Discussion Starter · #7 · Dec 6, 2016 (Edited)

4

:hammer:hammer:hammer

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Beairsto Racing

· #8 · Dec 6, 2016

You will soon learn that an improperly maintained turbo bike has a short fuse.
I would suggest that you go slow and research more about your particular system.
Is there a small water tank in the tail section?
Are you going to tidy up the loose wires and hoses?

KAUAIHD

Discussion Starter · #9 · Dec 6, 2016

Well that's the issue with this bike and why I'm here on the forums. At this point I'm 99.9% certain that this kit has been assembled in some guys backyard, the guy who gave it to me was fed up with it and spent way too much money on it and that's why I have it now, he also didn't really know anything about the bike.
I can't find any kit that come's with all the same components as this kit, especially taking into consideration the internally gated turbo.
I've got some experience with turbos, but everything that I know is from Subaru's and Mitsubishi's and never anything that had water injection.
The only water tank is the stock overflow tank.
And I'm definitely planning on cleaning everything up on the bike, but the first hurdle to clear is figuring out what all is going on with this set up.

Beairsto Racing

· #10 · Dec 7, 2016

Are you able to follow the wires from each pressure switch and see which circuit they are spliced into?

There's nothing wrong with a home built kit, and the builder likely utilized what he had available, to keep the cost down.
Its obviously a low boost system, but should offer pretty good bang for the buck...especially considering you're only into it for some critters.

Reactions: 1

HeJason

· #11 · Dec 7, 2016

I see the scavenge pump dangling there. That turbo does not look like it should require a scavenge pump. The centerline of the turbo (where the bearings reside) is above the oil filter, and that should be plenty high enough to gravity feed to the oil in the pan. The thing may smoke, and the previous owner may have tried to rectify the issue with a scavenge pump. It may just have needed a rebuild. :cheers

KAUAIHD

Discussion Starter · #12 · Dec 7, 2016

As for the wires on these solenoids. So the first two solenoids each have a wire going to ground, then the other two wires are spliced together going into the third one which has the vacuum line going into it, and the the other wire coming out of that on is broken and isn't going into anything.
As for the vacuum set up right now he had the tube coming off the hot side of the turbo hooked into the first solenoid, then the vacuum line going off of that into the second solenoid, then that is going off to the waste gate actuator with the "1/8 air tool" spliced into it. You can see that pictured when you look at the photo of the fuel lines under the tank.
So I'm sure whatever he had going here was working good at one point in time, I just can't figure out what the correct set up for it is. Is there any reason why the power commander would maybe need to see what the vacuum/boost pressure would be?

And turbo rebuild. I'll start looking into that as well. Thank you!:cheers

oldgixxer

· #13 · Dec 7, 2016

HeJason said:
I see the scavenge pump dangling there. That turbo does not look like it should require a scavenge pump. The centerline of the turbo (where the bearings reside) is above the oil filter, and that should be plenty high enough to gravity feed to the oil in the pan. The thing may smoke, and the previous owner may have tried to rectify the issue with a scavenge pump. It may just have needed a rebuild. :cheers

When I saw the oil return line with what looks like some type of electric scavenge pump just hanging freely,I said oh damn this dude has a nightmare on his hands...but,don't get discouraged. Just like @Beairsto Racing mentioned,home made kit can and will make power.

I'd leak down the engine to see if the top end is in good shape,replace all the fluids,filters,remove the scavenge pump and the 2" flat oil pan;replace it with an OEM pan which will allow you do have a steeper angle which will facilitate in using gravity to drain oil from the turbo back to the pan. Unless its strictly a race bike,the flat pan is not needed(of course if you slam down from a wheelie,you could damage or crack the stock pan).

Internal wastegate. They are notorious for boost creep which can easily lead to catastrophic failure if not addressed. You can port/unshroud the inside of the gate to help eliminate boost creep,but switching to an external WG is the best route.

If the bike is running,don't ride it until you bring it to a reputable shop who builds and tunes turbo bikes regularly. You need someone who knows what they're doing verifying the tune in the bike is safe.

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8you4t

· #14 · Dec 7, 2016

Rob check your pm pls

Maj750

· #15 · Dec 9, 2016

Late entry here guys, yeah looks like a water inj switch pump and solenoid , power it up with key and bridge the pressure switch terminals to see if its functioning, if it is tidy it up and leave it there, better to have it even if its not needed than not to have it and find out it is ..
if you have no way of monitering how the bike is running take it to a dyno with turbo experiance and get it checked

KAUAIHD

Discussion Starter · #16 · Dec 10, 2016

Definitely make sense, especially after I've done some reading up and educating myself on water injection systems, only problem is that there is no water tank on the bike, and correct me if I'm wrong please, but engine coolant definitely can't be the source of injection? Because the only fluid tank on the bike is the coolant overflow tank.
Also there's no dyno on the island, or even a performance shop for that matter. Just backyard mechanics and dealerships here.
I'm thinking my best option is going to be to go ahead and bypass all that craziness and see what happens and also get a wideband A/F so I can monitor it. The bike runs, but rough, and I've certainly never ridden it.

Maj750

· #17 · Dec 10, 2016

So the supply hose to that little pump just ends up under the tank ? , all you need is something like an aluminium drink bottle , like the bicycle guys use ,
Mount it up in the tail somewhere ,
People do some interesting things, some work well and others not so much, it is possible the previous owner used the existing reservoir if its connected into the system
your pump may not have enough pressure to work on the pressure side of the turbo either , looks a bit like a windscreen washer pump, if so it will work fine on the turbo inlet, as long as the water jet is not a concentrated stream

If not on your island i know there are guys near you with experiance, that may be able to help you get started without hurting the bike , ask around ?

logging is better than trying to read a gauge when everything starts happening fast , you need to be focused on the road at that time

Reactions: 1

RoadManiac

· #18 · Dec 21, 2016

KAUAIHD said:
I traded him a couple of ferrets actually. Of course the bike is a mess but... ferrets.
.

Best quote ever :woot

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