I have a 1999 std Busa engine that I've mounted in a custom made Ali. Box chassis. I'm building a one off fast road car as a bit of a toy. And I'm stuck! I plan to keep the motor stock as its fast enough for what I want. I've looked at your web site and think you have what I need to get it running? I have all the original loom and ancillaries but it looks way too complicated and over the top? I would like you if possible to tell me what I need. I need a simple loom, I assume a new ECU? In time I want to have a power shift on it but that’s another budget. Can you supply costs for this? My idea is to have a paddle shift off the steering wheel. Do your looms just plug in? What electrics do I need to save from the old loom? I assume I need a charging circuit and a ignition circuit? I'm not too worried about lights etc as these can easily be done on a separate switched circuit. Also do I need to alter the charging rotor thing? If so is there an exchange option for this part? How does the old one come off? So in summery could you please list out what parts I need to buy from you with prices and supply some simple instructions to enable me to do it!! Have you a full typical circuit diagram showing what parts of the existing loom/wiring I need to save? The engine does run but I know it can be much simpler. In your loom do you cut out most of the silly sensors? Does the std fuel pump (mine is on the back of the engine) plug straight in? is it a simple plug in start up and go system? I don’t want to make an expensive mistake here.
Fortunately you have detailed everything you have and everything you require. The installation of our system will be extremely simple by comparison with what you have there. Most of our harness will simply plug in to the original coils and sensors and what sensor you don't require will simply be eliminated. The only update we have carried out recently to our wiring harness is to change the injector connectors to make them more user friendly for future engine updates, but it is a fairly simple process to either add or make simple adaptors to convert from the standard Suzuki injectors to our wiring harness (there is no cutting of our wiring harness). If you are ok with a heat gun and a crimp tool, it is no more than 1/2 hours work. There are instructions within the installation instructions of the kit that show you in pictures how to modify the connectors, which you would remove your existing harness. The connector kit is included in the price. If you feel this is something you would not like to tackle for yourself, simply send us your sub harness and we will charge you 1/2 hour to carry out this work for you.
The charging circuit is relatively easy to modify but we do make a simple charging harness, which simply plugs into the generator and the regulator pack and then gives you 2 wires for positive and negative.
The small modifications you require to carry out our simple wiring, again if you feel that this is not an area that you are comfortable with, these components could be sent to us and we could modify them for you at the same time.
Your original fuel pump can be used, the only issue you could potentially have is that on the motorbike the petrol tank is mounted about the engine and therefore the fuel is gravity fed to it, when fitting it to a car you would need to ensure that the pump is mounted lower or at least at the same level as the bottom of the fuel tank, so you may need to reposition it. Alternatively, if your budget allows, you could a more traditional supply and return system and replace the fuel pump, fuel rail and fuel regulator to suit. I have not quoted you for this at this moment in time as you will better for yourself as to the installation of your car and what is and is not possible.
The generator trigger wheel is easily changed with the correct Suzuki tool or if you are suitable mechanically minded, it wouldn't be too difficult to produce something for yourself. Effectively you need to remove the generator cover, then there is a bolt retaining the generator rotor which locks it on to a taper and key. You simply undo the bolt, which exposes an external thread, the Suzuki tool is then tightened into this thread, there is then 2 flats on either side of the generator, which can be held with a spanner. This then pulls the generator off the crank, the generator itself on the early engines such as you have, has 8 teeth and you require a 24-1 which is fitted to the 2003 - 2007 engines. Although in the past some people have tried modifying the original motor, because metal has to be add in to some of the gaps, they usually damage the magnets of the rotor itself, so we do not recommend this option. It is best to hunt through eBay or similar to look for a second hand unit, new units are available but are very expensive.
Once the system is fitted and the throttle position sensor is adjusted, which can be done with a volt meter, with the standard map loaded which we would supply in the kit, your engine will be ready to run and use. Download the pdf below for fitting instructions of our wiring harness LM9A4-GSXR-M-OMS-2 fitting instructions.
The system you are looking at is, we believe, the simplest on the market and we supply this kit worldwide to trade and retail alike. If you wish to upgrade your engine and other components associated with it, it can be easily done. You mentioned about Powershift, the standard wiring harness that we supply has a Powershift connector built in and the ECU will be programmed and ready to use it as standard. You can simply then order the Powershift unit, which you fix to the lever on the gearbox and connect the other end of the cable to your steering wheel paddle or gear lever.