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Suzuki 800 Intruder Club & Forum
Welcome to suzuki800 Intruder forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, VZ800, VS800, C50, M50, Intruder / Boulevard / Marauder.

You will need to register before all the area's become visible, before doing so please enter & read the first thread in the Introductory area

It will only take a minute to register & it would be great to have you on board
This is a free to access and use site.
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A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
 
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 EFI conversion on VS800

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DIYer
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EFI conversion on VS800 Empty
PostSubject: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeWed May 19, 2021 8:09 pm

Hi all,
Well, please excuse my English but it is not my native one. After some struggling with weak rear cylinder and misfiring, followed by carbs inspection and refreshing and purchase of new fuel pump, finally I threw the towel and decided to take the easier way. The switch to EFI was on the table. The motor proved to be mechanically in sound condition. I didn't found any similar EFI conversion on this bike so this is probably the only existing EFI conversion on VS800.
Here is the beginning:
EFI conversion on VS800 49528675323_f401e70ecb_k

EFI conversion on VS800 49528674718_90b75bcd65_k

EFI conversion on VS800 49529407442_28dd496fde_k

EFI conversion on VS800 49529180196_ba285f6b2f_k

EFI conversion on VS800 49528673718_8c8afb8480_k

EFI conversion on VS800 49529406702_28ce30b1a9_k

Here are the baked generator coils. Fortunately still functional and no short to ground or interna in the coils. Later will take care for that too.

EFI conversion on VS800 49529406492_98f8e5ab89_k

EFI conversion on VS800 49529406277_96d7a05320_k

EFI conversion on VS800 49529406067_a5a70b1c7f_k

EFI conversion on VS800 49529405892_14afc4f353_k

The coil connectors to the regulator/rectifier:

EFI conversion on VS800 49529405717_87539fd98f_k

Here is where the new regulator will be wired but ... later:

EFI conversion on VS800 49529405537_23558df311_k

Needed new crank position trigger wheel with much more resolution:

EFI conversion on VS800 49529405337_a39bdf211e_k

DIY 24 tooth trigger ring/wheel and rotor/FW removing clamp:

EFI conversion on VS800 49528671738_78d6be60d4_k

EFI conversion on VS800 49529404957_2c3f847756_k

EFI conversion on VS800 49528671448_ae0f408e59_k

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EFI conversion on VS800 49529404187_897130248c_k

EFI conversion on VS800 49529403907_cc3a0140a3_k

At the same time the Ducati Monster 796 throttle bodies transformation has begun. I bought the throttles on ebay.co.uk for 29GBP. I choose these because of the similar CID as the VS800 and the low price (incl. he injectors and TPS sensor):

EFI conversion on VS800 49529403622_a071479af3_k

Had to modify them because of the limited space in the frame:

EFI conversion on VS800 49528670183_1cbb5dc36c_k

EFI conversion on VS800 49529176356_ad2643f4c2_k

EFI conversion on VS800 49529176161_87aef5bd3b_k

EFI conversion on VS800 49528669443_07d15155c0_k

EFI conversion on VS800 49529175941_38e9590de1_k

Decided to use the OEM crank position/rpm sensor:

EFI conversion on VS800 49528669268_1c14e78a7b_k

EFI conversion on VS800 49529397297_681366cb8e_k

EFI conversion on VS800 49529402182_f8a60ba495_k[

EFI conversion on VS800 49528669063_7053895ebf_k

EFI conversion on VS800 49529401887_3c94a37d6c_k

Deciding where to place the missing tooth based on the Megasquirt manual:

EFI conversion on VS800 49529174496_9cf6f650c9_k

Had to be very cautious because this is an odd fire V-Twin engine and the correct place is where the cranking rpms are relatively stable/constant, i.e. no compression strokes:

EFI conversion on VS800 49528667503_7c56746b38_k

EFI conversion on VS800 49529400767_f2aaf9d4c6_k

Let me post now because I don't want to lose the uploaded so far.
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DIYer
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeWed May 19, 2021 8:58 pm

EFI conversion on VS800 49529400572_e93bcd61fd_k

EFI conversion on VS800 49529173486_ec1e7d65c9_k

EFI conversion on VS800 49529173211_ebc1a3ecf7_k

EFI conversion on VS800 49529172326_afb9825b38_k

There is no space for the tps sensor so I had to move it down:

EFI conversion on VS800 49528665693_8956b42c2b_k

EFI conversion on VS800 49528665238_25821a16cb_k

EFI conversion on VS800 49528665098_d30a2fd898_k

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EFI conversion on VS800 49529329956_a2838b951a_k

Using the OEM throttle cables:

EFI conversion on VS800 49529557467_f9bba26103_k

EFI conversion on VS800 49528825688_22feb36a92_k
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DIYer
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeWed May 19, 2021 9:31 pm

EFI conversion on VS800 49528825433_f0578a83be_k

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EFI conversion on VS800 49528824418_945bb260e4_k

The throttle adaptors because the Ducati ones have 45mm ID compared to the Suzuki's 36mm:

EFI conversion on VS800 49529327626_606c44f868_k

I didn't want so bigger throttles but that's how it happened. I expect more "jumpy" throttle responce and probably some more power.

EFI conversion on VS800 49528824008_7af3385f3b_k

The work on the rear throttle begun

EFI conversion on VS800 49529555402_fb45e0e7aa_k

EFI conversion on VS800 49529555262_4bab7c01a8_k

EFI conversion on VS800 49529555097_75378470fe_k

EFI conversion on VS800 49528823378_e2bc169a65_k

Had only about 80mm to fit the throttle between the frame bars:

EFI conversion on VS800 49528823378_e2bc169a65_k

EFI conversion on VS800 49528823073_d0cd9d7af2_k

EFI conversion on VS800 49529326266_b326b876fd_k

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EFI conversion on VS800 49529441727_ca0d6c93e5_b

EFI conversion on VS800 49528822023_1958ce4930_k
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeFri May 21, 2021 7:58 pm

EFI conversion on VS800 49529325241_fd02a0528f_k

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EFI conversion on VS800 49529298581_026119a6ef_k

EFI conversion on VS800 49529525702_4f780d2528_k

The GM 1 bar MAP sensor:

EFI conversion on VS800 49529298091_274e895247_k

The BOSCH idle control valve:

EFI conversion on VS800 49528793508_dd897c33d1_k

EFI conversion on VS800 49529296996_fdaac08624_k

EFI conversion on VS800 49528791903_eef39df433_k

EFI conversion on VS800 49529523132_14a5a07555_k
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DIYer
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeFri May 21, 2021 9:01 pm

EFI conversion on VS800 49529522782_731f942856_k

EFI conversion on VS800 49529294871_97f5acbe5f_k

The fuel filter:

EFI conversion on VS800 49529294706_15fe5f5882_k

EFI conversion on VS800 49529294706_15fe5f5882_k

EFI conversion on VS800 49529294076_54a4dce1e6_k

EFI conversion on VS800 49529294076_54a4dce1e6_k

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EFI conversion on VS800 49528789863_8af87c59dc_k

EFI conversion on VS800 49528789633_5e71f660c1_k

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EFI conversion on VS800 49529293036_745b035956_k

EFI conversion on VS800 49529292831_b150312507_k

The WBO2 bungs on both downpires:

EFI conversion on VS800 49529292221_46f53537e9_k

EFI conversion on VS800 49529519967_0fc99201f9_k

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EFI conversion on VS800 49528754933_5e1d856a22_k

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EFI conversion on VS800 49528752963_8c09b83388_k

EFI conversion on VS800 49529485162_3acacc98a0_k

The IAT sensor placement:

EFI conversion on VS800 49528751723_7266a63dc8_k

The COP ign. coil swap:

EFI conversion on VS800 49529255831_0f1fba2de2_k

EFI conversion on VS800 49529255676_ee5f519d92_k

A VAG COP:

EFI conversion on VS800 49529255466_21ceb0d9fc_k

EFI conversion on VS800 49528750963_6081366423_k

EFI conversion on VS800 49529483457_4d556a712a_k

EFI conversion on VS800 49528750443_0f50d2f0d4_k

EFI conversion on VS800 49528750143_96d7cebf8e_k

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The Ducati fuel injector:

EFI conversion on VS800 49529250046_c6394ac77a_k

EFI conversion on VS800 49529478057_9383c29996_k

EFI conversion on VS800 49529477837_bd8ab4537a_k

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EFI conversion on VS800 49528743733_6e57d0a2c6_k

EFI conversion on VS800 49529248336_08b7c84542_k

EFI conversion on VS800 49529248176_0b66182e3f_k

EFI conversion on VS800 49528725823_de949dfd99_k
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeMon May 24, 2021 7:44 pm

The fuel regulator & housing:

EFI conversion on VS800 49529458527_4ec9213c58_k

EFI conversion on VS800 49529230031_96d83cf17a_k

EFI conversion on VS800 49528724543_c4d4d2d479_k

EFI conversion on VS800 49528698863_f885584e30_k

The Ducati throttles as they came from UK ebay:

EFI conversion on VS800 49696378578_8f19d793d3_k

My WBO2 controller and sensor kit. Later will receive one more kit for the other cylinder. The Microsquirt ECU has option for independent cylinder fuel corrections based on its own WBO2 sensor readings. That means much better fuel control and MPG. The fuel control is already in my hands :-)

EFI conversion on VS800 49696397428_e88c90390a_k

EFI conversion on VS800 49696399203_0a40d2e2a3_k

These are out forever! There's no way back!

EFI conversion on VS800 49696942436_c60b724f13_k

Here is a scope of the original trigger signal and 1st cyl coil control:

EFI conversion on VS800 49698138026_41fdb892cd_k

Here are the two coils control signals:

EFI conversion on VS800 49698449632_47457c0422_k

The new crankshaft trigger wheel with 24-1 teeth:

EFI conversion on VS800 49698752072_47bf9b8a39_k

EFI conversion on VS800 49701121786_4a0815652a_k

The DIY WBO2 cable extension to the WBO2 controller mounted under the seat. Two extension cables for both sensors/cylinders:

EFI conversion on VS800 49701470087_6de2cfca41_k

EFI conversion on VS800 49700627118_60cb786aa9_k

The first wireless (WiFi) ECU connection to the laptop:

EFI conversion on VS800 49701161471_b7bdb408c9_k

For sequential engine control I had to install synch sensor:

EFI conversion on VS800 49701468932_6b05e451c4_k

EFI conversion on VS800 49701160381_9559f36fdc_k

EFI conversion on VS800 49700626163_b4e363d1e2_k

EFI conversion on VS800 49701468117_57f05a380a_k

Adding a WiFi module to the setup:

EFI conversion on VS800 49700625773_db9f2f3903_k

How the WBO2 bungs install began:

EFI conversion on VS800 49701159331_f2f854142d_k

EFI conversion on VS800 49701467452_af2a8a24ea_k

EFI conversion on VS800 49700624888_fd44abc126_k

EFI conversion on VS800 49700624398_bea0b7a0a5_k

EFI conversion on VS800 49701157466_9bf829de10_k

EFI conversion on VS800 49701156941_4004d7783b_k

EFI conversion on VS800 49700622763_fb05ac2c56_k

EFI conversion on VS800 49700622573_56f51200f4_k

First start attempt:

EFI conversion on VS800 49701156121_a611c81b66_k

Vacuum connections:

EFI conversion on VS800 49701464162_45f95830f5_k

Making scope files for the MSExtra forum help desk:

EFI conversion on VS800 49700621683_77f3d5e2c9_k

Removed forever:

EFI conversion on VS800 49700621433_3e0744422e_k

EFI conversion on VS800 49700621183_cd14600783_k

The engine control put on paper:

EFI conversion on VS800 49700620603_49778d8fbe_k

The front cyl with the coil and the sync sensor in the back:

EFI conversion on VS800 49701462397_0c6785b95a_k

First views of the Android based dash on my smart phone. There are four different screen layouts with option for showing what engine parameter to be shown:

EFI conversion on VS800 49701150676_bf77ced6a6_k

EFI conversion on VS800 49700617103_e88fd142a1_k

EFI conversion on VS800 49701462027_d21b8ec35d_k

EFI conversion on VS800 49701461742_de9bde73fe_k

The new coil control signal capture:

EFI conversion on VS800 49700619438_678ebde089_k

A working screen on my tuning laptop:

EFI conversion on VS800 49701460637_fe098fc01b_k

Connected:

EFI conversion on VS800 49701152131_68ec80b16d_k

Added heatshield to protect the fuel lines and the fuel regulator from unwanted temp. rise:

EFI conversion on VS800 49700618093_80638936c8_k

EFI conversion on VS800 49701151566_b242ea1100_k
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DIYer
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PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeMon May 24, 2021 8:02 pm

EFI conversion on VS800 49700617628_6a2744da26_k

Some older pics when I was still trying to save the carbs:

EFI conversion on VS800 49704567836_1704a8f53f_b

Few of the many adustment screens:

EFI conversion on VS800 49708272728_d6b670947b_k

EFI conversion on VS800 49708806841_abd65744ac_k

EFI conversion on VS800 49708271578_e1c6b12bf0_k

That's all for now. Still more to come.
Thanks for watching!
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Badger
Valued Member
Badger


EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeWed May 26, 2021 1:57 pm

Wow ...  that's the most detailed and complex post I think I've seen here.
Mostly the chat is about fairly basic stuff.
well done.    EFI conversion on VS800 276246

DIYer likes this post

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ArnoldinIdaho
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeFri Jun 04, 2021 2:39 am

What planet are you from?  Certainly a highly advanced engineering culture!
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mcitours
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EFI conversion on VS800 Empty
PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeFri Jun 04, 2021 2:27 pm

Staggered by the commitment to this project.
I have been playing with Tune ECU on a KTM RC8R but this is way more sophisticated...
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PostSubject: Re: EFI conversion on VS800   EFI conversion on VS800 Icon_minitimeFri Jun 04, 2021 9:39 pm

Hey guys,
Your comments made me feel very proud. Thank you very much! But let me stop with the chat and post the next portion of pictures.

Just recently started the engine suddenly stopped. A bit later it appeared the fuel pump has failed due to unknown reason. Probably some weld remainings in the small fuel tank have been sucked up and have damaged the pump impeler. I consider this as my fault as I was lazy enough to skip the fine strainer on the fuel pump inlet. Thought the petcock's strainer would be enough:

EFI conversion on VS800 49815656108_e70f4e93e2_k
EFI conversion on VS800 49816192116_fb18ff5bdf_k

Bought also a new battery:

EFI conversion on VS800 49816502247_4fccd72663_k

Decided to move the idle valve over the cyl. head and replace it with an external pump:

EFI conversion on VS800 49816191706_cd356d7517_k

EFI conversion on VS800 49816501992_250749ba1a_k

EFI conversion on VS800 49816191491_2313359907_k

EFI conversion on VS800 49815655363_8755a3e490_k

EFI conversion on VS800 50215025841_4a931425ad_k

EFI conversion on VS800 50215043191_54a15219ea_k

EFI conversion on VS800 50214521563_69940f118c_k

Meanwhile the chosen external low flow and low current Walbro pump appeared as non available worldwide anymore, and also due to the its higher price I decided to go back to the intank pump location. The new 3bar pump was ordered again from ebay.uk for about 15 euro.

EFI conversion on VS800 50215313552_dd5887d18f_k

...this time with additional strainer:

EFI conversion on VS800 50215042966_681e864396_k

Soon I found that an intank designed pump can't be used as partially intank because of fuel leaks around the el. terminals. Hence my next step was to make it fully closed in the tank:

EFI conversion on VS800 50215311552_ee4740a10e_k

EFI conversion on VS800 50215312932_cdfef72ad8_k

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EFI conversion on VS800 50215044336_7cb9678c17_k

EFI conversion on VS800 50215313302_1496f0f589_k

First time out of the garage:

EFI conversion on VS800 50215312347_fdae587ae3_k

... and the first drive on EFI:

EFI conversion on VS800 50214520328_bb5f5f6fb3_k

EFI conversion on VS800 50215108093_ae82173014_k

First trip out of the city:

EFI conversion on VS800 50314976541_51575a3a11_k

EFI conversion on VS800 50314975766_2e25b72902_k

Later will post some videos from the project.

Thanks!
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