[4wheeljive]

I can wait to see it on the road

[JrZook]

Cheers guy!

Still got quite a few bugs and rework to do but I'm inching my way forward!! Can't wait for my EFI manifold and play with my fuelling algorithms. Should be the first injected XV250 worldwide

[Rhinoman]

Getting it running is good, a big step forward

[JrZook]

It's a huge step forward! Always great to hear a project like this fire up an engine for the first time .

Now have to dive into the more tricky stuff like interrupt priority handling and issues with interrupt masking. I'm not a software guy by no means, but I'll get there eventually. At least now I know that light exists at the end of this tunnel

[Che]

Success! Great project JrZook, only just caught onto this but i've read it all now

As they say there's only one way to eat an elephant - one bite at a time.

[JrZook]

After a few late night head scratching sessions, starring blindly at the code and watching the misfires happening in random fashion on the oscilloscope while sinking a few rumbos (hells yea I'm a great multitasker) I finally clicked on to what was causing the issues! Ended up being some of my awesome dumbass coding additions. Man I must have been right on the opposite side of sober when i merged them together. Some A-grade quality fail right there!

Anyways rewrote a few of the extremely dodgy sections and now on the spin bench tested to ~2700RPM there is absolutely no Ignition misfires. Woooooooooooooooo!!! Added bonus, I also measured the ignition timing on the C.R.O and we are spot on!! WIN!! Next step is to connect it back up to the bike and see how this ignition system performs and check the actual timing with the timing light. If that works out then I'll box the unit up, strap it to the bike and go for a test ride to check for anymore misfires at higher RPMs!!

The coding framework for the fuel injection is 90% written. Just need a couple more weeks on it and to integrate it with the existing ignition code and then all I'm waiting on is the injection intake manifold and the rest of the EFI hardware.

[JrZook]

Haven't done a great deal on it as I've been pre-occupied with other projects such as a 2-1 exhaust system but I have still been progressing on it. Been spending quiet a bit of time on the PC tuner and diagnostic side of things which is starting to look descent as well as functional. Managed to make up a nice and simple patch cable to the stock Yamaha harness to run the digital ignition timing at this stage. Just gotta enclose the ECU into some sort of box and mount it to the rear guard for a test ride to check if all the bugs in the code are gone and the VR conditioning circuit is triggering reliably.




Stay tuned!

[JrZook]

So I finally got some new bits and pieces in woooooooooooooo! This will eventually become the on board EFI engine monitor/tuner as well as a performance measuring device (PMD). It will also be a platform to develop the next digi speedo setup. The PMD part will be capable of measuring wheel speed/acceleration and 1/4 mile times etc and thus will become a valuable tuning aid. Unfortunately a don't have a dyno with me so this will have to do to get it up and running decently before I need to spend some coin on a few dyno runs.



So what we have here on the top left is the 3 axis accelerometer unit. Below that is the 20x4 black character LCD with white backlight (should look sweet once i power it up) and on the right are a pair of Bluetooth modules. Yep gonna attempt wireless data transfer between my ECU and the PMD. Should work out sweet!! I hope

[Jackson]

This is awsome but I like

[4wheeljive]

How much awesome can you cram in this bike

[JrZook]

4wheeljive wrote:

How much awesome can you cram in this bike

Is that a challenge?

[SLYjoel]

I found the video of that other project you were working on.

http://www.youtube.com/watch?v=MXW0bx_Ooq4

O_o

[oozuk]

SLYjoel wrote:

I found the video of that other project you were working on.

http://www.youtube.com/watch?v=MXW0bx_Ooq4

O_o

They gotta be taking the piss yeah !?!

[sogone]

Reall ooz?... Taking the piss?

[JrZook]

SLYjoel wrote:

I found the video of that other project you were working on.

http://www.youtube.com/watch?v=MXW0bx_Ooq4

O_o

Well managed to do a bit more work on this in between the million other projects.

The ECU finally has a more stable and portable enclosure.


Made up a simple and quick mounting bracket outta alloy so I can actually go for a road test.



Connected her up to the bike with my revised code (more sober edition) and she runs like a dream!! No noticeable misfires now! Even took her for it's first ride with the ECU controlling the ignition!! Was just a super short low speed run but I'm proud to say that its ridable!! Woooooooooooooo!!!



Currently running an ignition map that on paper follows the stock RPM based timing curve of the XV250. Timing peaks at 27 BTDC from 3000rpm onwards to redline. Managed to find an SRV250 (twin carb'd high output engine version) service manual and interestingly enough the timing peaks at 32 BTDC from 4500rpm onward. So it will be interesting to see how much there is to gain by tweaking the ignition timing!

Next step is the connect up both the stock TCI unit and my ECU to the spin bench at the same time and check how close my actual ignition timing is to the stock system.

[4wheeljive]

10 points Mr Dan that is really cool

[PJ.zook]

Project sounds like its going great, good work!

[JrZook]

So I was confident enough to take the bike out for a quick fang up the motorway with my ECU controlling the ignition timing. Good news is I didn't have to push it home!!

Its nearly there but still not 100%. I do get a miss-fire here and there tho they are completely random so they are super hard to track down! Could be a number of things such as: Electrical noise, VR triggering issues and/or software issues.

To try and find these gremlins I need to get this:

to spin up to 8000RPM so I can check the output on the oscilloscope and hopefully find the source of the miss-fires.

Currently directly driven off the drill I can only achieve ~2800RPM.
So anyone got any suggestions for me?

[bakerboy]

die grinder? or angle grinder?

[SLYjoel]

Well, you've made that setup, no?

Make a small gearbox for it with a 4:1 drive. You look like you have the skills.

[atari4x4]

belt drive, big pully driving small pully

[4wheeljive]

Chain and srockets from a bike for a reduction ?

[JrZook]

4wheeljive wrote:

Chain and srockets from a bike for an overdrive ?

Yea im thinking this way. What else out there has a small chain or toothed belt drive systems? Photocopiers or something?

Chain/belt driven over-drive will be the easiest to set up.

[SLYjoel]

RC Car?

Try a hobby shop?

[JrZook]

Well in the last few weeks I've been giving my brain a bit of a break on the electronics side so I decided the bike needed a new exhaust to replace the old rusted out POS as well as an oxygen sensor bung welded in for tuning once the EFI starts happening.

Note: I'm not welder, bender, metal worker so this is not the neatest set-up, plus I was only going off idea's in my head as I haven't seen nothing like this on this bike before, so go easy

First of all I had to rip off the old junk stock system and salvage the machined flanged off both the front and rear header pipes. I also reused the alloy exhaust clamp off the front pipe.


General concept from my head to pipes layout out on the floor.


Forward facing 1.5" bend connected to the 1.25" bend with the flange plates. It just fits!!


Scientifically testing for clearance


Lots a bashing, cursing and some welding


Welded an O2 sensor bung into the front pipe. Positioned it roughly around ~6" from the head to make sure it gets into operational temperature.


Some paint and walla! Very functional exhaust with O2 sensor capabilities

[JrZook]

Rode it to uni today with the ECU controlling the ignition! I made it!!! WOOOOOOOOOOOOOOOO!!

A few very slight random misses but that's about it. It's very rideable!!

[shakes]

JrZook wrote:

Rode it to uni today with the ECU controlling the ignition! I made it!!! WOOOOOOOOOOOOOOOO!!

A few very slight random misses but that's about it. It's very rideable!!

Thats sensational! Can I congratulate you and express my hate and jealousy in the same sentence? Have been watching this with great interest as a mate is keen on a similar project. It's wayy out of the realms of my knowledge but close to his so it might be a goer yet.

[shakes]

Oh and the next step is to cut that rear fender wayyyy down, remove and remake the rear sub-frame so the seat can be nearly on the tire, and a set of clip on's

[Damo]

I told him he needs more rake, bigger front wheel and ape hangers

[shakes]

http://www.flickr.com/photos/10153012@N04/3633927900/ it's a bit hard to pull off with a springer rear... But here is the general idea (not the best example but the first I found)