Bax Cave Winter Project..........

**Bax** · 02-13-2021, 09:03 AM

Letting the fillet forming layer setup.... Again, the hardest part is not touching it too soon....

---Bax

**Bax** · 02-13-2021, 02:52 PM

Plastic weld is all cured and the T-MAP sensor affixed to the airbox. The initial test fitment on the bike was a bit difficult for the location determination when the kit was it three pieces, flange, sensor, & connector. I had to use measurements to check the connector clearance to the frame and thought the centerline mounting was appropriate. I'd say it's a good fitup...

---Bax

Attached Files

**DiverRay** · 02-13-2021, 03:44 PM

5mm is good. Remember the airbox is bolted to the frame, so it should not move.
Looking nice!

**Bax** · 02-14-2021, 02:57 PM

Continuing on with the modernization today. Sensors, sensors, sensors for the new ECU. MAP is an integral sensor on the ECU so that'll be covered by vac tubing the carb balancing ports to a 4-1 vac manifold back to the ECU. TPS is already on the TB array. I've installed the intake air temp and air box pressure sensor yesterday. I have two combo fluid pressure 0-10bar and temp sensor -40-140C on the way for the engine oil and fuel rail. These Bosch sensors have a male M10-1.0 threaded connection which is readily available for any gauge takeoff on aftermarket AN-6 fuel fittings making the fuel system monitoring rather easy to port into. I have the fuel pump setup mostly roughed out and I'm currently having a pump tank made up to feed the rail so nothing to play with yet on the fuel front.... Now the oil pressure/temp..... The oil temp will take place of the coolant temperature input that liquid cooled engines would normally use. I poked around for a few good places to monitor oil temp, low hanging fruit would be to use the drain port on the pan but useless for pressure and sensors under the bike are less than ideally placed. Considered a modification of a spin on filter adapter with a sensor port, again it' would be under the bike. Contact sensor on the oil supply pipe to the head, hmmm, again useless for pressure and the oil is already thermally lazy compared to water/glycol mix and the external pipe temp monitoring scheme would just add delay to an already sluggish response time. Use the existing pressure switch port, nice placement, plenty of room with no float bowls crowding it, going for it. So I want to keep the oil light function so I'll just program an aux output for the existing sw: (if >300rpm & oil pressure <4.5psi) or something like that. Now the sensor fit, never easy.......the OEM switch uses 1/8 BSPT threads (I have a collection of Japanese built machines at work, BSPP and BSPT are a total PIMA) which is not popular for sensors anymore. Adding to the mismatch is the clearance to the overhanging head. I'm going to have to make an adaptor with 1/8 BSPT male threads and M10-1.0 female threads with the ports at least 15 degrees offset. First guess is that this is not a readily stocked item....... This is going to be a fun one to make up.

---Bax

**Bax** · 02-14-2021, 07:00 PM

Still scheming up the sensor fit...It'll be close but depending on the class fit of the sensor threads and connector added dimensions I may just rethread the sensor to 1/8 BSPT. Not too much there to cut into with a die but it may just work.....

thread specs on M10-1.0
Major diameter 9.974mm
Minor diameter 8.9mm - 8.6mm depending on 4g or 6g tolerance

BSPT minor diameter d3 on attached chart 8.5mm, might leave enough to bite and seal with o-ring instead of the thread mesh......

Thinking it may be worth "rolling the die" (see what I did there...).

---Bax

Attached Files

**Bax** · 02-17-2021, 06:33 PM

Thinking it's going to fit....... The connector mates over the sensor and is well clear of the head in place. I'm just going to attempt to rethread the new sensor. I'll have it in the scroll chuck for sure and run the die squared up against the tail stock.

---Bax

Attached Files

**cajun31** · 02-18-2021, 12:29 AM

Your project is moving along. If you would share with all of us all of the components you are working with. I have been doing a bit of research and would be interested in a list of all the components your employing. Might help all of us ... both in understanding and who knows we might have some beneficial input So far .... your work looks phenomenal.

**Schming** · 02-18-2021, 07:11 AM

Originally posted by Bax

Thinking it's going to fit....... The connector mates over the sensor and is well clear of the head in place. I'm just going to attempt to rethread the new sensor. I'll have it in the scroll chuck for sure and run the die squared up against the tail stock.

---Bax

This may be an option for your oil pressure sensor.
The SS fitting was made by a member that is sadly no longer with us, but I'm sure can be duplicated.
The fitting replaces a banjo bolt and has an 1/8" NPT for the gauge. Not sure of the size of the banjo bolt, thinking 10 x 1.0, but the hole/port in the shaft of the bolt needs to be spot on as it feeds the bearing on the middle drive I believe.

Attached Files

**Bax** · 02-18-2021, 10:38 AM

Schming Nice pressure take off application. I did consider using that machining port access for this sensor but never took out the plug bolt as the pressure switch port seemed like a fitting placement. If I don't kill the sensor with the re-threading attempt I'll check it out again in more detail. What do you normally see for oil pressure there? Clod, Hot, Idle, Rev'd ---Manual has it at 42psi "cruising speed".

---Bax

**Schming** · 02-18-2021, 12:38 PM

Originally posted by Bax

Schming Nice pressure take off application. I did consider using that machining port access for this sensor but never took out the plug bolt as the pressure switch port seemed like a fitting placement. If I don't kill the sensor with the re-threading attempt I'll check it out again in more detail. What do you normally see for oil pressure there? Clod, Hot, Idle, Rev'd ---Manual has it at 42psi "cruising speed".

---Bax

O.P. is about 20 to 30 psi + or - a few lbs. idling at startup with enrichener on.
At idle when fully warmed around 4 to 10 psi.
Fully warm cruising in fifth gear with the 750 FD 30 to 40 psi
IIRC

**Bax** · 02-18-2021, 12:41 PM

Originally posted by Schming

O.P. is about 20 to 30 psi + or - a few lbs. idling at startup with enrichener on.
At idle when fully warmed around 4 to 10 psi.
Fully warm cruising in fifth gear with the 750 FD 30 to 40 psi
IIRC

Schming Thanks. Around what I was expecting.

----Bax

**Bax** · 02-18-2021, 06:01 PM

Originally posted by cajun31

Your project is moving along. If you would share with all of us all of the components you are working with. I have been doing a bit of research and would be interested in a list of all the components your employing. Might help all of us ... both in understanding and who knows we might have some beneficial input So far .... your work looks phenomenal.

cajun31 Here are a few of the main components and a brief on my selection. I'll be sure to do a final report when I've got it back on the road.

The throttle bodies. I got these configured in an array with the setting 78-83-78. Best measurements I could get with the Mikuni set on the bike measured this spacing. I think 84mm is the book center spacing dimension but I used what was actually measured. Very helpful folks at Jenvey.

SS 38-45mm Spigot Body 1 Injector XX

https://store.jenvey.co.uk/throttle-bodies-and-components/throttle-bodies/ss-spigot-individual-body/ss-38-45mm-spigot-body-1-inj-xx-ssxx-xx-xx1

PLEASE CALL TO DISCUSS YOUR BORE AND SPIGOT REQUIREMENTS. SS Individual fuel injection throttle body with 1 injector position. Complete with right hand linkage (when ordering 1 body) or standard interconnecting links when ordering a number of bodies. These are often used for motorcycle throttle bodies. Please note that this item is made to order and can't be refunded..

Injector info is at start of this thread.

ECU. I am using the EMU Black. It will fit nicely in the same location at the TCI box and can drive coils,15amp output, directly without the need for an igniter module. I considered the megasquirt build and checked out the other popular makers, Haltech, Fueltech, Holley, Bosch and many others.....

ECUMASTER EMU BLACK

https://ecumasterusa.com/products/ecumaster-emu-black-standalone-ecu?variant=8318139039805

ECUMASTER EMU BLACK is a universal engine control computer that manages the operation of spark-ignition engines, and is designed to work with the most advanced and complex currently available engines. It is the successor to our proven system, the ECUMaster EMU. Common applications for the EMU Black are modified race cars, passenger cars, motorcycles, boats, and stationary engine applications. EMU Black features sophisticated strategies for drive-by-wire throttles, providing a wide range of control with advanced algorithm reliability (fault / error) and failsafe provisions. System capabilities will increase over time because of the ease of upgrading (free) firmware (eg. New strategies, trigger patterns, CAN-Bus data streams). The EMU Black is one of the best values in engine management available anywhere. Built-in hardware includes a 4 bar MAP sensor (for reading manifold pressure up to 43 pounds of boost), built-in wideband controller (just add your choice of a Bosch 4.2 or a 4.9 sensor, no external controller needed), 6 built-in high current ignition drivers (can drive smart or passive coils, up to 12 smart coils for waste spark), 2 EGT inputs, CAN and Serial on board, on-board Drive By Wire control, and much more. All of these features in a beautiful CNC Aluminum enclosure that's small enough to fit in your hand.(Click here to jump to downloads links) SPECIFICATIONS: Operating temperature range: AECQ100 Grade2 (-40 to 105C) Reverse polarity/short circuit protection: YES (built-in) Operating voltage: 6-22V (resistance to transients according to ISO 7637) Housing: IP 60, CNC aluminum, designed by ECUMaster Dimensions (mm) Weight (g): 150x72x31, 390 Electrical connectors: 1x24, 1x39 FCI specifications PC Communication: USB (via the Windows software suite), serial, CAN-Bus OUTPUTS: -8 Injectors (5A protected, low side, high impedance only, resistor box must be used for low impedance injectors) -6 Ignition (15A rated, protected, for passive or active coils, up to 12 cylinders in wasted spark) -6 Auxiliary Outputs (5A protected, low side) -'Full bridge' rated to 7 Amps, can be used as separate outputs or 2 x H-Bridges -WBO Heater: Rated to 5A (low side) INPUTS: - 9 analog inputs with a resolution of 10Bits, 0-5V (protected) - 2 EGT input (type K thermocouple) - 2 knock sensor inputs - Lambda probe: Bosch LSU 4.2, LSU 4.9 or Narrowband - 3 Trigger Inputs (crankshaft, 2x camshafts) Hall / VR (defined in the software) - 1 vehicle speed sensor (Hall / VR) (Front/Rear wheel speed coming soon) - 1 dedicated Flex Fuel Sensor input - 3 switched inputs (switchable to ground) SUPPORTED SENSORS: -Temperature: IAT, CLT, Oil temp., AC EVAP temp, Fuel Temp via Ethanol Content Sensor -Pressure: Oil, fuel (defined characteristics), Air pressure (MAP/EMAP) -Lambda: LSU 4.2 (embedded controller), 4.9 (embedded controller), narrowband probe, or external controller -Frequency: Vehicle speed sensor (VR / HALL) Gear sensor (sensor or calculation) IGNITION: 6 output channels (passive and active coils - software definable, up to 12 cylinders in wasted spark) Supported triggers: N-1, N-2, N-3, N 1, Multitooth, Subaru triggers, trigger Nissan, Lotus Elise, Audi trigger, Renault Clio Williams / Alpine, Colt 1.5CZT Ignition Table: 2 tables 16x20 (load x speed), resolution of 0.5 degrees Per-Cylinder Ignition Corrections: Yes Coil Dwell Correction: YES, wizard selectable for popular coils, or can be user-set Additional correction strategies: CLT, IAT, TPS vs MAP, Nitrous, Idle, Knock sensor, LC, Pit limiter, ALS, Flat shift, Timers, Acc.enrichment FUEL: Injector Outputs: 8 High Impedance Injectors (full sequential, up to 12 semi-sequential) Adjustment of injection angle: 0-720 degrees Latency correction for voltage: YES, wizard for popular applications, user-definable Fueling strategies: VE based on "speed density" or "Alpha N" strategies, with additional modifiers Air charge temp: Based on IAT and CLT VE Tables: two 16x20 (Load x RPM), accuracy 0.1% Individual cylinder trim: Yes Staged injection: Yes Additional Correction Strategies: Oxygen sensor Corrections, EGT correction (per cylinder), BARO, TPS vs MAP, TPS vs RPM, warmup, Nitrous, LC, ALS, ASE, Fuel pressure, Knock, Leanout protection Real-time correction based on Lambda sensor: Uses Lambda / AFR target map KNOCK SENSING Channels: 2 Frequency range: 1-20kHz, 3rd order AAF Sampling: Ignition event driven, knock window Definable events: ignition retard, fuel enrichment, dash light indication Variable valve timing: Supported strategies: VVTi, MIVEC, VANOS, Dual VANOS, AVCS Number of variable cams supported: 2 Control Strategies: PID based on closed loop referencing 'CAM angle target' (12x12) Idle Control: Types of control: PWM solenoids (2.3 lines), 'drive-by-wire', stepper motors (unipolar and bi), ignition cut, cut fuel Control Strategies: Open / Close loop, Ignition modification, Ignition cut VE Corrections: Yes, Alpha-N Corrections: Load (air conditioning clutch, cooling fan load), or definable analog inputs DRIVE-BY-WIRE: Control Strategies: Advanced 3D PID Algorithm plus static friction compensation Supported e-throttles: All DC motors requiring less than 6,5A, 28 popular E-throttles supported in DBW wizard menus 'PPS characteristic maps': 3D tables referencing commanded VS. actual throttle angle and RPM, driver switchable Downshift Blip Support: Yes Rally-Style Antilag Support: Yes TRACTION CONTROL: Strategies: Delta RPM, gear compensation, F/R wheel speed Reduction of torque: cutting the ignition using the 3D map (16x20) Sensitivity control: with 10 positional rotary switch BOOST CONTROL: 'Boost ref' and 'target-tables': 2 sets of maps 10x10 (TPS vs RPM) Control Strategies: Open / Closed loop (PID based) Corrections: Gear, VSS, IAT, EGT, TPS, RPM CAN BUS: CAN standard: 2.0A 125, 250, 500, 1000 kBps Supported protocols: CAN ECUMASTER, Motec M800 Set 1, Haltech E8 E11v2, Pectel SQ 6, AEM Supported vehicle protocols: E46 BMW, Citroen C2, Mazda RX8, Ford ST, Polaris RZR, R53 Mini Cooper, Fiat 500, Renault Clio, Lotus, Ford Fiesta, Ford ST, EVO X (AYC support) and many more ... ENGINE PROTECTION: Lambda guard: Engine protection for lean conditions, safety strategies for fuel enrichment, partial throttle closure, and reduction of boost pressure User-definable critical values for sensors: Yes Displaying error or critical value: Yes (user definable) Overtemp protection: Yes (Oil Temp and CLT), definable by the user, RPM limit Protection for low oil pressure: Yes, definable by the user, turn off the engine if necessary Low Fuel Pressure Protection: Yes, delta fuel pressure compensation, RPM limit, turn off the engine if necessary Protection for high EGT: Alarm, per cylinder fuel trim, boost limit FLEX FUEL: Measurement of ethanol content: Yes Fuel Density Compensation: Yes Blending between maps: VE, IGN, Lambda / AFR, Boost, Cranking fuel, ASE, Warmup Fuel temperature / PWM Correction: Yes SPORT: ALS: 2 independent settings ALS, DBW support Shift light: for each gear Launch control: Yes Gear cut: Yes (open loop), DBW blip supported source: Switch, load cell, CAN Pit limiter: Yes Rolling anti lag: Yes OTHER: Unused Injector outputs repurposed as Aux outputs: Yes Input/Output functions: fuel pump, radiator fans, start/stop button, nitrous oxide, map switching, 3D PWM outputs, A/C clutch control, main relay control, speedometer, tachometer and other ... Password Protection: Yes, 2 levels of control Timers: Fuel, Ignition, Boost timers controlled by virtual outputs Serial protocol for dash displays: AIM, RaceTechnology Autotune: Yes Built-in oscilloscope: Yes Logging: Log in real time to a PC, log to external loggers using serial or CAN (eg. EDL-1 Ecumaster Data Logger) ________________________________________________________________________________The EMU Black is supplied with the following physical resistors in the box: (2) 2200-ohm (2K2) (2) 1K-ohm (2) 120-ohm (used mainly for CAN bus termination) DOWNLOAD LINKS: THE EMU BLACK MANUAL IS LOCATED IN THE CLIENT SOFTWARE UNDER THE BLUE "?" HELP MENU ICONEMU BLACK CLIENT OFFICIAL RELEASED SOFTWARE (scroll down to EMU BLACK section)EMU BLACK CLIENT BETA SOFTWARE BOSCH 4.2 AND 4.9 O2 SENSOR WIRE DIAGRAM FOR EMU BLACKFIRST START CHECKLISTBASE MAP INDEXBASE MAP CONFIGURATION (video)LOGGING BASICS (video) EMU Black Pinout

Fuel pump. Got a 30mm CNT in tank fuelpump. Appropriate flow sized for feeding the the 4 injectors, will not add too much heat to the fuel from excessive flow, and it will not draw much amperage. I'm making up a can for it to sit in.

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https://www.fuelpumpfactory.com/products/new-30mm-intank-efi-fuel-pump-piaggio-vespa-gts-i-e-super-touring-300-2011

I've only roughed out my plans for the ignition system, nothing purchased yet. If/when I sort out a cam position sensor this may be (my goal) the XS running on 4 independent coils........

This is the guts of the BOM I got going so far Jim

---Bax

**Bax** · 02-19-2021, 05:56 PM

cajun31 Jim, This is the info for the combo T-MAP I used on the air box and the oil/fuel pressure & temp. The EMU Black has SW selectable input terminations. The temp sensors inputs will be set to 4.7k ohm pull up.

---Bax

here is the catalog link, both sensors are in section 7

https://www.bosch-motorsport.com/media/downloads/catalogs/printkatalog_2020.pdf#page191

pics of the sensor pages

Attached Files

**cajun31** · 02-19-2021, 06:25 PM

The ECU you have selected is an amazing device. I have been reading the owners manual and basically you can do just about anything you want to with that mounted. I was curious about your selection of sensors too. I tip my hat to you on the entire undertaking. Definitely not for the faint of heart.

**Bax** · 02-23-2021, 05:43 PM

Got the bulk of the "in tank" fuel pump can made up today, 2" stainless tube with an end cap. First I'll be making up some centering rings to support the fuel pump and then I'll make up the access flange with the outlet fitting and power feed thru. Got a couple of barb fittings to place radially as inlets from each side of the tank. ---Bax

Bax Cave Winter Project..........

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