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Thread: Thread for throttlebodies, pics and dimensions

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    Pit Crew Decade Plus User TepiTheFinn's Avatar

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    Thread for throttlebodies, pics and dimensions

    Everybody, please take pics and dimensions of your throttles.

    These are off from 2003 Kawasaki ZX12-R. Here's some pics and dimensions. STD Injectors are good for 180bhp.
    These can be easily spaced for different lenght engines.
    Zetec cylinder spacing is aprox. 92mm







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    Bodger

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    Re: Thread for throttlebodies, pics and dimensions

    Lot of bike TB info and measurements is here:
    http://www.msefi.com/viewtopic.php?t=6627

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    Re: Thread for throttlebodies, pics and dimensions

    Hers a link to my project thread on feoc, shows my gsxr 1000 bodies on a st170 inlet, nearly done, lots of pics

    http://www.rs20004x4.com/test/index.php?showtopic=32855

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Nice one Should try and get Asad on here, I helped him do his conversion a while back

    She's built like a Steakhouse, but handles like a Bistro

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    Re: Thread for throttlebodies, pics and dimensions

    Quote Originally Posted by RChambers
    Nice one Should try and get Asad on here, I helped him do his conversion a while back

    Yeh he's been helping me soooooooo much, big thanks goes to him, pestering him on msn every night

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    Racer luz008's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    that website is good 1.8esc - helpful for others.
    What i would advise if you've not put them on yet is to dremel the intakes on the st170 manifold so the are circular and not the oval shape. The is excess plastic top and bottom which can be sanded off then polished smooth. It makes the transition from circle TB's to oval inlet easier.
    Also are the vac take off's needed as i've been wondering what to do with mine.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Nah you only need the vac take off for the brake servo in shopping cars. No need on ours really, just fit a bias box

    She's built like a Steakhouse, but handles like a Bistro

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    Racer luz008's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    cool thanks for that - not using a servo anyways (well waiting for someone to answer my brake question so i can get master cylinder fitted )

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    Re: Thread for throttlebodies, pics and dimensions

    Quote Originally Posted by luz008
    that website is good 1.8esc - helpful for others.
    What i would advise if you've not put them on yet is to dremel the intakes on the st170 manifold so the are circular and not the oval shape. The is excess plastic top and bottom which can be sanded off then polished smooth. It makes the transition from circle TB's to oval inlet easier.
    Also are the vac take off's needed as i've been wondering what to do with mine.
    yeh done that already lol look on page 3

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    Spanner Monkey

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    Re: Thread for throttlebodies, pics and dimensions

    Hi guys, for what it's worth, I have bought some throttle bodies. I know the lads at Blacks bike breakers so they let me in the back armed with a vernier to figure out the easiest solution to get the right tbs for my zetec. Eventually decided on the later gsxr 750/1000 throttle bodies. These have a minimum machined bore of 42mm, with no cut out at the top for an injector. I noticed on the bike that there are 4 rubbers between the body and head. These are a push fit (as per samco hose) on the tb side and a convenient flat with two c/sunk screws at the back a bit like a dcoe. The big plus that I saw was the rubber manifold is a perfect internal round fit at the tb (no lip) and it changes to be an oval (same as the bike head port) at the joint face. I am mid way through custom building my own ali manifold that matches the bike oval at one end and the car oval at the other end, if you see what I mean. A photo is enclosed of the assembly on the car. I believe the pitch between cylinders to be 91.8mm, the bike bodies are 80mm centres so I therefore turned up 9 x 11.8mm long bushes to extend the gaps (which can be seen in the photo. The linkage I have extended by welding extension tabs on 3 of the body butterfly arms. This works a treat.
    Biggest headache now is to modify each body to take a bosch 'yellow' injector kindly loaned by sticker Paul of passionford fame.

    Then of course a fuel rail is needed. Will probably shorten a cossie rail, but may do a custom one in ali, depending on available time.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Wow that looks really good. I wish I had the facilities to make something like that as I bet it flows better than the ST170 setup

    She's built like a Steakhouse, but handles like a Bistro

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    Spanner Monkey

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    Re: Thread for throttlebodies, pics and dimensions

    Cheers Rich, I would like to say I could market them however this thing has been a bitch to make, not to mention expensive on materials plus our work is shutting it's machine shop so I thing they will remain a 1 off for the time being.

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    HERES A LINK TO THE XROC FORUM. BOTH SETS IN THIS THREAD WERE KNOCKED UP BY ME, I CAN SUPPLY HELP IF ANYONES DOING SIMILAR. I ALSO HAVE SURPLUS ALLY TUBE AND FUEL RAIL (BLANK OR SORTED).
    LOOKY HERE... http://www.xrstyle.co.uk/forums/inde...howtopic=12850

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Looks great, how much would you charge for the inlet manifold and fuel rail just out of interest?

    She's built like a Steakhouse, but handles like a Bistro

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Fuel Rail For 600 Setup As Shown £35 Ready To Fit Inc Fittings. 750 With Plastic Parts Is £30 Exchange.
    Manifold Subject To Offers, They Have Fetched Up To £150 On Ebay. Does This Forum Have Pm Facility?

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    Re: Thread for throttlebodies, pics and dimensions

    Click on the user name and send a private message

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    easy when you know how !!! thx mate.

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    Re: Thread for throttlebodies, pics and dimensions

    Ive finally finished the manifold for GSXR1000-Zetec. Was a bit nervous fitting it all together as I was never 100% sure that the ports would line up perfectly after at least 25 hours hard work. Thank F&+* all went well.
    BTW there is a 50% chance of me acquiring a CNC vertical machining centre in the near future so I may be able to do 1 off tricky bits and so on if all goes well. Ill keep you informed.....

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    Spanner Monkey

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    Re: Thread for throttlebodies, pics and dimensions

    Lurvely job

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    That looks fantastic

    She's built like a Steakhouse, but handles like a Bistro

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    Thumbs up Re: Thread for throttlebodies, pics and dimensions

    Thanks for the kind words folks, hopefully first fit within the next week or so and get the engine mounts made up.



    still doing panel work like it's going out of fashion.

    Anyone familiar with a phrase " I've done this much I might as well........."

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    nice job there mate !

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    my latest effort for my own project.

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    Pit Crew Decade Plus User TepiTheFinn's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    nice looking
    i would turn them upside down so that the injectors spray into top of port where main airflow occurs.
    i believe they are underside on GSXR too
    Cheers, Tepi

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    Bodger cortina_gt's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Nice job Alladdin. I like the ally fittings you have in the fuel rail. Did you make these? I have been tryng to figure the best way to extend the stock GSXR rail. Are you going to use the stock GSXR injectors?

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    tepi.. i might well do that,they are indeed up the other way on the bike, is the flow much greater at the top

    cortina-gt yes i hope they will be ok as its a std motor for now., i made the fuel rail parts from drive pully stock hence the shape ,they are easy enough if you have access to a lathe. or make 3 strait bits and tap the end 2 plastic t's to take fittings

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    Pit Crew Decade Plus User TepiTheFinn's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    std gsxr 750/1000 injectors work up to 200bhp
    Cheers, Tepi

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    Spanner Monkey tarmac terriost's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    i would like to run tb's on my 2.0 16v
    mondeo
    would like to build up a kit bit by bit ,but i dont want to run bike tb's
    think about running something like this

    but build it up but dont know which bits to get
    like manifold the main tb's trumpets fuel rail and injectors
    and then there is which managment system to run
    would like to keep the price down to dont want to go to mad
    already have fast road cams
    waiting to go in will have the head played with too
    also looking into rs1600 exhaust manifolds need to know what is envoled to fit one of these
    got a few other ideas to mod the engine to get more bhp from it
    thinking of increase the comp ratio would like to know how about going about this apart from skimming the head also
    thinking about having the block bored out to 2.1 and having it wire rung and run a copper gasket
    i would need to run apr bolts in the bottom end for strenght
    also can anyone reconmend places to get all the bits from or who makes them custom etc

    have been look at burtons website
    at weber tb's
    omex
    etc
    any info would be ace
    also is there anywhere that does paddle clutches for the old mondeo
    mrk 2 mondeo ghia saloon
    17" tsw reflexs bomz kit
    fast road cams/obx pulleys
    drop 30mm eibach springs mongoose catback exhaust
    4.1 ceramic coat exhaust manifold
    custom down pipe/highflow cat

    list to do :-
    st bodykit 300mm disc conversion+rear disc
    underdrive pulley custom management 45mm throttle bodies gasflown big valve head
    comp ratio increased 11:1


    looking for a mint 4x4 rouse motorsport 304r sapphire running std (260bhp) or stage 3 set up

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    As your engine is in a Mondeo you can only run the Weber Alpha Gold kit as it is the only one that will pass emissions tests without any hassle. It comes as a complete bolt on kit but isn't cheap. I would look at doing what Percy did with he mondeo as a supercharger would help a lot in pulling a lardy mondeo along with some pace Costs are very similar if you import the bits yourself.

    She's built like a Steakhouse, but handles like a Bistro

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    and in a mondeo install you will need to research the clearance issues ( not suggesting you didnt already !)

  31. #31
    Spanner Monkey tarmac terriost's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    bulk end clearest is not a problem
    so i could only run with the alpha gold?
    could i run the others or not
    what problems do they give ?
    mrk 2 mondeo ghia saloon
    17" tsw reflexs bomz kit
    fast road cams/obx pulleys
    drop 30mm eibach springs mongoose catback exhaust
    4.1 ceramic coat exhaust manifold
    custom down pipe/highflow cat

    list to do :-
    st bodykit 300mm disc conversion+rear disc
    underdrive pulley custom management 45mm throttle bodies gasflown big valve head
    comp ratio increased 11:1


    looking for a mint 4x4 rouse motorsport 304r sapphire running std (260bhp) or stage 3 set up

  32. #32
    World Champion Decade Plus User RChambers's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    You can runs others (My Emerald ECU can do closed loop lambda) but they need custom looms making up and setting up. The weber alpha kits are almost plug and go although not many people can remap them, where as ecu's like Emerald and DTA, etc usually supply you with the software. I still say a supercharger will work better in a mondeo as its a bolt on kit and retains the standard wiring and ecu. I think you will come up with all sorts of problems if you bypass the ecu as it controls things other than the engine doesn't it? Look to USA for cheap tuning parts

    She's built like a Steakhouse, but handles like a Bistro

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    Bodger

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    Re: Thread for throttlebodies, pics and dimensions

    Your right about the ECU controlling other things. Im not having any bother with the running of my mondeo so far (the one in the pic above) Im using megasquirt, and most of the extra controls from the EEC IV can be added to megasquirt, which im using for fuel and spark management

    And im aware that my engine bay is a mess just now. lol. Stilll messing about with it, so il fix it later

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    Bodger cortina_gt's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Is there a preferred direction to face the injectors when GSXR throttle bodies are used? Most installations seem to have the injectors on the top. I saw in another post that it might be better if they were facing the other direction.

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    tepi sugested in this post that by placing them undrneath ( like they are on the bike) they spray into faster airflow... i dont know if this setup has been varified as better tho on a zetec. since even race builders seem to place them on top i doubt they will suffer there ?

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    Spanner Monkey tarmac terriost's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    when browsing the web the other day i came across this
    wanted to know will bike tb's fit to it and which ones?

    also is it possible to run 8 injector set ups etc
    with mega squirt ?
    mrk 2 mondeo ghia saloon
    17" tsw reflexs bomz kit
    fast road cams/obx pulleys
    drop 30mm eibach springs mongoose catback exhaust
    4.1 ceramic coat exhaust manifold
    custom down pipe/highflow cat

    list to do :-
    st bodykit 300mm disc conversion+rear disc
    underdrive pulley custom management 45mm throttle bodies gasflown big valve head
    comp ratio increased 11:1


    looking for a mint 4x4 rouse motorsport 304r sapphire running std (260bhp) or stage 3 set up

  37. #37
    Bodger

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    Re: Thread for throttlebodies, pics and dimensions

    cant say anything about the manifold, but yes megasquirt will run 8 injectors no problem. Put 4 on each channel, and you can use them simultaneous, alternating, or staged where you only run 1 set below a set value. then teh second set come in above the value. The value can be rpm, MAP, or TPS

  38. #38
    World Champion Decade Plus User alladdin's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    you need the original bike mounts or a set of these ....
    http://www.turbosport.co.uk/showthread.php?t=112093

    but be quick as im redundent anytime now and loose use of machines !

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    Spanner Monkey tarmac terriost's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    they look bleed fab m8
    what are the diamentions sizes of those mounts
    will need them to fit zetec head and zetec manifold like the pic above.
    so need to know specs of them height,width,length,diameter of the holes in the mounts where tb's fit also the thickness of the plate they are mounted to manifold with the hold diameter to fit onto the studs etc


    how do i work out the spaces on the manifold to fit the tb's and those type of mounts?


    so with something like those mounts i could get the gxr tb's to fit the manifold i posted up also
    just need to know how can i get round the injectors and fuel problem,like which ones to run what to use fuel rail wise and what about a loom for the rail etc
    sensor wise i would ditch the lot
    maf,air temp,but keep the idle control valve or not so that idle doesn't go ape or can i get away with out the valve when running the mega squirt ecu
    also which type ecu would i need for the job ?

    also what bits and bobs will be need for the job?
    mrk 2 mondeo ghia saloon
    17" tsw reflexs bomz kit
    fast road cams/obx pulleys
    drop 30mm eibach springs mongoose catback exhaust
    4.1 ceramic coat exhaust manifold
    custom down pipe/highflow cat

    list to do :-
    st bodykit 300mm disc conversion+rear disc
    underdrive pulley custom management 45mm throttle bodies gasflown big valve head
    comp ratio increased 11:1


    looking for a mint 4x4 rouse motorsport 304r sapphire running std (260bhp) or stage 3 set up

  40. #40
    Pit Crew Decade Plus User Group4_Mark2's Avatar

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    Re: Thread for throttlebodies, pics and dimensions

    Quote Originally Posted by Sparker View Post
    Im using megasquirt, and most of the extra controls from the EEC IV can be added to megasquirt, which im using for fuel and spark management

    What version of megasquirt are you using? I am thinking of building my own but want to know which is the best version to use

    Tom

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