After I finish designing the intake and injector manifolds, I am going to need to figure out the air routing and filter setup. The current filter on a PC800 is equivalent to an HA-8089 from K&N. It has a filter are of roughly 10×6 inches. Arguably, the air intake on the PC800 is a bit restricted so it could be bumped up larger on my FI conversion project. A replacement that I have seen on other makes of bikes is to drop in a K&N cone-style filter. One particularly attractive one that would fit on the end of the throttle body is an R-1260. It’s inexpensive (about $30 online) and easy to get. It has a conveniently larger filter area. However, space constraints will dictate what I can put in. I will also want to be pulling air from as far forward as possible on the bike. Otherwise, I’ll be sucking in hot engine air which won’t help power any. When I am making up the air filter/intake manifold, I will also need to remember to put a couple of bungs on it for my MAP sensor and other such measurements and references.
Injectors for the PC800
From my calculations, based upon the current PC800 fuel pump putting out 36 liters of petrol in an hour, I need to get injectors that are rated for about 30 lb/hr or greater. There are some Delphi 30 lb injectors for sale on DIY Auto Tune for $50/each. I know I want high Z injectors to minimize current requirements. This also means they’ll be saturated injectors. The next size up of injector that DIY Auto Tune carries is a 37 lb model that is marine grade. The anti-corrosion properties would be useful although that big of an injector might be too big. The fuel pump that I have on the way would be able to support the larger injectors although unless I have a turbo or some other form of forced air, I probably wouldn’t need to be injecting that much fuel.
I’m not sure if I want a conical spray pattern that will probably deliver superior atomization or if I want a dual squirt gun pattern that will be able to be directed to hit both intake valves. Both would have their benefits.
Summit Racing has several types of injectors for around $35 each in the right general size category. For instance, the FAST 30332-1 would be about the right size. The ACCEL 150132 at 336cc/min would be about right, too. I’m not sure if there is a big difference in quality between brands or not though. I’m willing to pay a little more for a better injector that will last longer and be easier to use on this project.
Unrelated to injectors… I think I am going to go for the Mega Squirt II so that I am ready to expand to full spark control after I get fuel injection squared away. I also think I will spend the extra couple of bucks to put a knock sensor on my engine.
Wide band oxygen sensors and controllers
Wide band oxygen sensors and controllers are a difficult bunch of products to figure out. Some sources I’ve read claim that I don’t need one and shouldn’t spend the money on it. Other sources say it’s absolutely necessary if I am to achieve a decent tune. Also a wide band O2 sensor can lead to closed-loop control which helps improve economy for cruising.
Strangely, the MegaSquirt products only support narrow band O2 sensors natively. Otherwise, you have to have a separate controller for the wide band sensors to work with the MegaSquirts. There used to be a DIY board available but it seems to have fallen by the wayside. Now the main two options that are available seem to be the Innovate LC-1 and 14Point7. The 14Point7 would end up costing less although there seems to be more readily available support for the Innovate LC-1. Also the LC-1 is a smaller package that would more easily be installed and appears to be weatherproof. On the high end, I will be out $209. On the low end, about $150. Is the extra 50 or so bucks worth the DIY AutoTune support? Also there are a lot of people using the LC-1 successfully…