Kawasaki ZRX turbo project
11-04-2005, 09:26 AM
#1
0.0 BAR
Thread Starter
Join Date: Oct 2005
Posts: 7
Kawasaki ZRX turbo project
Here's how to create a 200 HP motorcycle that's VERY streetable & fun to ride. 
I started with a 2003 Kawasaki ZRX that I purchased new in 2003. After doing all of the normal NA upgrades(pipe, jet kit, K&N = 128/86 SAE at the rear wheel), I still wanted more power. So, why not turbocharge it?
I found a guy in Wisconsin, Troy Stuart, who has been making basic turbo kits for this bike for about 3 years. I talked to Troy & soon a kit showed up at my door. Troy's kit utilizes pre-owned Garrett T25 turbos that were originally on the DSM 2G cars. No special mods are done to the turbo to convert it to use on my 1.2L engine. The kit also uses a log style exhaust manifold, in-line electric fuel injection pump, Mallory 4309 FP regulator, carb plenum, and a custom-made charge tube that incorporates a "pitot" tube that pressurizes the float bowls with boost pressure(this is necessary since the kit is a "blow thru" the carb design). All fittings, hoses, & bolts needed to get you up & running are also included. Picture instructions make installation relatively easy with normal tools. All this for less than $2500. Initial boost starts at just over 3000 rpm & I have full boost(12 psi for now)by 4700 rpm.
Here's an abbreviated picture chronicle of the install on my bike. Hope you enjoy the show.
Mock up before powder coating.
Modified gas tank with Pingel fuel valve & return line fitting.
Powder coated plenum & charge tube.
Ceramic coated exhaust manifold & dump pipe.
Partial assembly
Fuel pump
Mallory FP regulator
K&N filter & Hallman Pro MBC
Autolite gauges for boost, A/F ratio(DJ Wideband Commander), and fuel pressure(small boost gauge)
Dyna 2000 ignition module incorporates boost avtivated ignition retard. GM 3 bar MAP sensor behind Dyna.
Dynojet Wideband Commander
Finished bike with +6 swingarm extensions.
I started with a 2003 Kawasaki ZRX that I purchased new in 2003. After doing all of the normal NA upgrades(pipe, jet kit, K&N = 128/86 SAE at the rear wheel), I still wanted more power. So, why not turbocharge it?
I found a guy in Wisconsin, Troy Stuart, who has been making basic turbo kits for this bike for about 3 years. I talked to Troy & soon a kit showed up at my door. Troy's kit utilizes pre-owned Garrett T25 turbos that were originally on the DSM 2G cars. No special mods are done to the turbo to convert it to use on my 1.2L engine. The kit also uses a log style exhaust manifold, in-line electric fuel injection pump, Mallory 4309 FP regulator, carb plenum, and a custom-made charge tube that incorporates a "pitot" tube that pressurizes the float bowls with boost pressure(this is necessary since the kit is a "blow thru" the carb design). All fittings, hoses, & bolts needed to get you up & running are also included. Picture instructions make installation relatively easy with normal tools. All this for less than $2500. Initial boost starts at just over 3000 rpm & I have full boost(12 psi for now)by 4700 rpm. Here's an abbreviated picture chronicle of the install on my bike. Hope you enjoy the show.
Mock up before powder coating.
Modified gas tank with Pingel fuel valve & return line fitting.
Powder coated plenum & charge tube.
Ceramic coated exhaust manifold & dump pipe.
Partial assembly
Fuel pump
Mallory FP regulator
K&N filter & Hallman Pro MBC
Autolite gauges for boost, A/F ratio(DJ Wideband Commander), and fuel pressure(small boost gauge)
Dyna 2000 ignition module incorporates boost avtivated ignition retard. GM 3 bar MAP sensor behind Dyna.
Dynojet Wideband Commander
Finished bike with +6 swingarm extensions.
had one built to 17:1 compression and spray 
