Busa turbo build picked this up as an ongoing project previouse owner douggy is a mate of mine who had a bit of bad luck when after it had spent time getting work done on it the mechanic who was test riding it managed to get some dick head who ran him over while stationary

damage was front end wrecked and frame damaged which were replaced then got offered to me to finish the job so went up to scotland and trailered it back leaving douggy with my k3

first thing i did was sit back look at it i love busas not the pretiest bike naked but ive always wanted one and i also wanted to build another fighter the turbo was a plus but it really dont need one i had to put my marc on it and the bike had lots of quality parts on it but not the way i would have put it together

so within a week engine was out of the frame and bike was in peices first thing i wanted to do was get infills made up to get the gap between the frame and tank sorted and also to get the frame powdercoated black also noticed that the frame had lugs on it that were of no use to me so get rid of those also sent the bike to a mate in newcastle (dave) who straight away said that he could make the tank look like one piece and would flow better dave did his magic and also sorted the frame out

whilst he was at it i decided i wanted the turbo boost in the tank and also a thermo for cooling again dave came up trumps first attempt we both agreed dident work so with the help of jim and steve we decided to put them in the tank and not showing. dave got the general idea put a little bit of a twist to it and it came out spot on biggest issue we had was if i had guessed the depth right

whilst all that was getting sorted i turned my attention to the front of the bike and decided it needed beefing up so got a set of thug yokes

so contacted sbd for info and took the bike to sbd for fault finding looks like the software was 4 years old got the ecu software upgradded and found the compensations inputed wrong so adjusted
t/bs still playing up and coolent sensor not steady, some more rewiring and change coolent sensor. back on dyno starts to map and run ok keeps loosing boost
furthur inspection in the workshop found that the headers were cracked,all the way around (main section were it goes 4 into one)
so good news all the probs found so far headers comming off monday when i get back from work then probably off to stainless dave to weld them up properly then back to ken to remap
bike rides lovely and he sorted out the throttle issue just needs to come onto boost recon kens used up a lot of favours on my behalf ,will post up the fucked headers once i got them off ,so much for rebuild and ride was showing over 300bhp on kens dyno but instruction to ken is not about the numbers its about usability so see what he comes up with

(july 2011 update)
Not a good day took took the turbo off in the process managed to damage the oil cooler,so need to buy a new one,headers wouldent come off the turbo on solid ,
off down to dans who managed to get three out last stud had to be cut off so now the turbo has to go down to a shop to get the remainder of the stud removed properly,
when he removed the headers as well as being cracked the metal gasket was split so another reason for loosing boostand city link failed to pick up the headers that need to get to dave for welding

what a couple of weeks
a big thank you to dan for sorting out the studs in the turbo, dave for welding and turning the headers around in 24 hours,esm for getting the header flange milled flat in one day
and kjb busa for the oil cooler and not forgetting exilefor giving us a hand to put the turbo back onall sorted and on the road rode great love the sound of the turbo winding up not sure what its currently pushing but its going back to kens to sort the idling and remap the turbo
got its studio shoot done today thanks will rob dave a good day out

whats next looking at a laminova oil cooler to sort out the clearance of the original cooler also they look trick sfc sorting me out a one off carbon headlight cover and a carbon cover for the air induct,looking into a new windowed clutch cover and possibly a wider rear wheel without getting silly, guaranteed will do more but for now just happy owning and rebuilding a busa turbo fighter

September 2011

laminova cooler fitted radiator welded up bracket had come loose also time insert sorted out for the sump thanks bill carbs synced up and now balanced went onto bills dyno running rich at approx 3500 revs but hey pushing 120bhp on pretty much idle so bills sorting out contact for me to get the mapping sorted out over the next 2 weeks should see 280bhp easy Update mbe system ecu not motad as first thought still a good unit but looks like we are going to have to buy the leads to map it software is available free so looks like bill will get the job to map it up

October 2011

leads bought original mapping sent to us via hole shot on bills dyno and not boosting hours of mucking about max boost 3psi looks like the 3bar mapping sensor is faulty so bill managed to get one trade, and back on the dyno, boost shows 9psi then drops back to 3 so still an issue.hour later found that the plenham chamber was trying to eject itself and was loose on 3/4 throttle bodies the result 15 mn later 175bp @ 6psi then 216bhp @ 7psi and last run 242bhp @ 8psi

left the bike at blls recons we still have leak so still looking for the missing 40 horses:) graph on photo album

people to say thanks to usall suspects oncus, exile, cavy . dave for the outsanding fab work on the tank and frame. scott fab work. dan at just motorcycles bill (dynomut) for help on the turbo and educating a southerner, ken cooper for set up .oss & dtp for help and encouragement and most importantly my mrs and daughter elise who aint happy that its got a single seat:)

The Spec:

Engine: hayabusa 2004 fully stripped and rebuilt new mains and big ends
cylinder head had the valve seats re-cut and lapped and some minor porting
bearings and seals heavy duty headstuds
heavy duty clutch springs
forged je pistons, barrel spacer
modded clutch basket billet clutch slave support bracket
garrett gt25/28 turbo charger tial 38mm wastegate small dump pipe k&n cone filter
alloy plenham chamber samco hoses inline thermo cooling sender

Frame: hayabusa 1999 frame lugs cut off and ram air ducts smoothed down powder coated frame modded aprillia /gsxr subframe billet coolent bottle

Front end: hayabusa 2008 forks radials,2008 front wheel ,carbon mudguard, billet thug yokes, brembo rs brake and clutch master cylinders, rizzomo res, renthal drag bars, one off risers, motogadget clocks and idiot lights, yamaha mt03 front light, one off clock and headlight bracket, matris steering damper with 916 style mounting bracket 120/70/17 pirelli diablo tyre

Rear end: spondon drag arm with 2.5lb noz bottle, stock busa wheel with wavy disc harris adjustable rearsets, ,200/50/17 pirelli diablo tyre

Bodywork: standard hayabusa 2004 tank modified to fit frame boost guage and temp built into the tank gsxr k6 carbon seat unit

Electrics: heavely modded loom, aux in seat hump one off billett plate tidy with built in flush mounting brake,tail,indicators leds, fuel m,ment MBE 9A4 ECU - modified harness to suit ecu- 3 bar map sensor - hd fuel pump heavy duty fuel injectors top hats and clips,eboost 2 boost controller new regulator rectifier 6 stages of boost, when set up at holeshot stage 1 287.6 r/w bhp 178.8 lb of torque (150lb of torque produced @ 5000rpm

made up, with one off risers to fit the k8 front end some renthal drag bars and brembo clutch and brake master cylinders got some rizzoma resoviours also wanted to change the clocks as they stood out to far so got hold of a set of motogadget clocks which worked well on the front. i hate indicators so did what i did on my last fighter and hid then under the master cylinders front light was a nightmare its all been done before was going to look at a mask but got put off it ended up looking at a yamaha unit which id seen on dans gsx and jims fighter dan sourced it for me (just motorcycles.net) and also made up the clock and headlight brackets which made the healight looks like it floating

next port of call was some wiring and tubbing, starter and electrics werte bunched up under the seat and the coolent bottle under the hump plan was to extend the starter and extras into the seat hump and replace the coolent bottle with an alloy unit external to the bike another issue was the ignition needed to be moved as it would look crap on the yokes so made up a mount and put it in the engine bay

whilst the engine was out picked up some samco hoses and refitted went for blue to break up the colour as i wanted it stealth but too muck black can make it look bland had to cut into them when i relised the motogadget clock dont have a themo reading on them and put in a sender replaced some bolts and gave the engine a clean down put the engine back into a lovely satin black frame and bolted it all back together coolent bottle remounted at the front and just checked all nuts and bolts

the busa had an zxr shock which i dont think was man enough for the job so repalced that with a busa 04 shock re.polished the spondon arm and highlited the logo put on a wavy rear disc from my old gsxr replaced the rear brake line and re-routed used my old nos bottle anf guage (not plumbed in yet thats for the future) had to do some work on the rear seat to make it fit right and got scott to make me up a numberplate tidy out of billet alloy picked up an led strip from custom dynamics which acted as brake stop and indicators and kept the undertray totally clean

so pretty much there before i painted the tank checked to see if the tank was airtight it leaked just like dave said it would and he did say its an easy fix he had done all the hardwork fabricating the tank so no issues. more worried about sending it back to him and it getting damaged in transport which had happened once already saying that when i approched several people about doing the job all i got was the oh its going to be expensive we got to take the filler out bla bla bla it looked like i was going to have to pet seal it did some reaserch and that was a defenate no no so went hunting again and came accross a bloke local who took one look at it said no prob done in two days cheap as chips as dave said no biggy just got to watch out for the rip off merchants

paint time loads of ideas in the end called jim down to my garage and we went over differant things ended back at my original plan keep the tank black white stripe it with a blue pinstripe that would flow with the blue and alloy billet petrol cap and samcos get some billet suzuki s as a logo,decided not to paint the gsxr k5 carbon seat unit just continue the stripes through it which would also tie it in with carbon frontguard and just a bit of polishing thank god dave the painter pretty much spent two weeks swearing at me he had a lot of work to do filling and profiling the tank and decided he dident like the tank just black and put some flake in it came out well i think

last job was to get my steering damper fitted and it was a tight fit in keeping with trying to keep the bikes lines clean opted for a 916 style fitting which sorted out that issue d day approched which believe it or not i was not looking forward to as the bike had not been started from the day i recieved it till 7 months later jim came down for moral support and we hit the button it fired up no prob sounds great

passed its mot mechanic took it for a spin said it wasent fuelling right got it home and decided to take it for a spin to clear its throat and yep it was defenatly playing up so booked in with ken cooper the master biggest issue was getting hold of a lead for the race ecu (great having all these trick parts not great if you need to get work done) eventually ken got what he needs and sorting he found loads of issues wastgate sticking no boost or boost no fuel and loads of other stuff hes findings as he goes along but hes getting there so hopefully on the road in the next couple of weeks ohh the joys of building a special (june2011)

(july 2011 update) so far its been a bloddy nightmare if it can go wrong it has starting with 2 weeks for a lead for the ecu better than spending 160 on buying one i supose one fuel hose was fractured,
sorted. bike was running lean on dyno hugh misfire no power after 180bhp. inspect and balance t/bs repaired pick up wire and replumbed turbo smart and rewired still wouldent respond to mapping
stripped out plennnum and throttle boddies checked pump and filter found the filter was fucked like proper fucked throttle bodies had bent butterfly repaired and replaced filter. re balanced
back on the dyno was better but now massively rich remapped but kept drifting in and out