3TJ - Coils and BDK Ram Air

[Kurlon]

Finally have my RR SP and am going through final prep for racing next year. (My budget got trashed for this year... bah.) I've got some small things to sort, I need new brake lines up front as one of the Goodridge units is leaking at the fitting, etc. I've also got a couple bigger issues to sort, one of which is an airbox.

Currently the machine is running flatslides, BDK tank, and no airbox or filter whatsoever. I've got a BDK airbox in rough shape to massage onto the machine, but see 3 main obstacles.

1) This is a hybrid motor so the carb mounts are in a slightly different spot, this should be easy enough to sort though.
2) My radiator looks to be too tall, blocking the snorkel. I've seen the suggestion to 'massage' the top with a rubber mallet for clearance but that scares the bejeseus out of me.
3) My coil leads are short enough that I can't route the plug wires in a way to make room for that snorkel to get through.

On #3 it's been suggested that I can just pop the wires out even though they're molded in, and push in longer replacements. Option 2 is lead extenders. I'm not that big a fan of either, if I'm pulling leads I rather have a positive lock via a screw in lead with retaining cap, and I don't like putting extra splice points and weight on the lines.

Is there a tested reliable replacement coil set that allows for replacement HT leads, or am I over-thinking replacing the wires on the stock coils?

[rockTJ]

....or you could replace them all with stick coils and make your own custom connector loom....

Would solve a few problems and give you a bit more room behind the headstock.

Chris

[Kurlon]

Only stick conversion I've seen is using CBR 600 units, but you end up with very different primary resistance than stock IIRC. I've got a V&H powerpak so I'm hesitant to drift outside OEM specs, although the stick setup would be cleaner... :D

Edit: Seems the 07 CBR600RR uses COP sticks with 1.6 ohm primaries... so two of them in series is 3.1 ohms, aka perfect. Guess I know how to solve this dilema now. I'll post up pics and details when I pull it off.

That'll just leave dealing with the radiator...

[rockTJ]

I have heard of R1's using renault clio coil sticks and vice versa. Just a thought.

I am going to be using R1 coils on my 3TJ and TBH I am not worried about the resistances for the moment, helps I have a spare BDK unit, but I can't see it doing too much harm.

Chris

[Taggyd]

if you have just open carbs at the min, the ram air may cause you jetting problems that you'll need to sort

[Kurlon]

if you have just open carbs at the min, the ram air may cause you jetting problems that you'll need to sort

I'm fully expecting that, fortunately I've got access to a dyno with a sniffer and an AFR gauge for the bike for real world data gathering.

[cajun]

Hey Kurlon, do you have any pics of the Airbox? And did you order it straight from BDK? Also keep us updated on the CBR coil process. I have those coils on both my NC29 and MC22.

[Evilchicken0]

The snorkel probably won't fit.
The standard rad needs to be modded, either cut at the top for the snorkel or, on a 400 dropped a bit. The problem is the 600's pipes won't let you drop the rad.
The second problem is the 600's head is higher so it will interfear with the snorkel.
The coils are simple though, just use Dyna Coils you can have the silicon leads made whatever length you want them and site them where you like.

[Kurlon]

Just played a little in the garage.

This is the easiest carb rack I've had the pleasure of taking off or reinstalling. I was GOOD at lighting fast carb changes on my GS500E, I can do this in half the time with a lil practice.

Anyways, the goal of today's experiment was to test fit the airbox itself, ignoring the snorkel. No go. I need to recut the openings for the carb boots. They need to move forward a good 1/3rd of their length. After that I don't see any issues with fitting the box itself. Seeing as I'll have to repair the bottom to make it seal properly anyways, I may try to recapture some more volume under the box, lots of room seeing as the fuel pump has gone on walkabout... :D

I'm half tempted to make a two piece box so I can gain volume from the area behind the cross bar the BDK box goes over. They used to do two piece setups on the 851s due to a frame brace being in the way back in the day so it's not new territory. MAYBE the extra volume will help with not being able to snake that snorkel through?

Evil, people have actually CUT their radiators for clearance before?! I'm assuming the regular radiator shop down the street isn't going to be able to do that service for me?

[Evilchicken0]

Yes you can cut a chunk out and then reseal it - you might want to get a grown up to help you on this though - ask your radiator shop.
If you can't get the snorkel in then you can consider cutting a slot through the frame bracing just back from the headstock then rebrace around it.