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Thread: Mates Kawasaki Z125 Turbo

  1. #1
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    Mates Kawasaki Z125 Turbo

    So a mate of mine was tossing up for a while whether or not to turbo his 125. I didn't have much input other than to lend a hand with the fabrication. Have always wanted to try my hand at something like this so it was a good opportunity. I don't have a whole lot of intricate photos right now but more than happy to grab pics of anything you guys are interested in.

    The basic outline of the build was -

    - Borg Warner (off a Smart car for memory).
    - E85
    - Megasquirt
    - Wideband for tuning


    These bikes have a surprising amount of space available. Some guys mount their turbos off the side of the engine, we went for right in front mounted as high up as possible.


    The intercooler my mate first supplied me was hugeeeeeee. Clearly wouldn't clear the turbo!


    Decided to work with what I had, and I cut down the intercooler (by roughly half). Used an angle grinder to cut the tanks, then a hack saw to cut the fins. Wasn't too bad to do, unfortunately none of my neighbours had a band saw so had to do it the old fashion way.


    Next step was to block off the uuuge 2.5" outlets. Throttle body & turbo outlet were both 32mm which worked our very well.


    We decided to mount the intercooler down low in front of the front wheel. Judging by the angles, the wheel shouldn't be able to flick anything directly into the core. It may cop some shit from the road etc so I've recommended to my mate maybe to use some mesh over the cooler to protect it as much as possible.
    The other issue was giving ourselves enough space for the oil cooler & pipe work.

    This is the turbo outlet side. Was not ideal having to run piping past the exhaust housing, but didn't have much choice (will both need ceramic coating & wrapping). The fairings will need to go back on so had to keep that in mind.


    Decided to do the piping in alloy. Keeps the weight down quite a bit and I get a lot of practice with my alloy welding

    This is the turbo outlet side. Was far quicker making this one


    This is how much clearance the oil cooler will have. Not 100% sure I will mount it here just yet.


    That's about it so far. Quite a lot of fucking around dummying things up to see if/how they fit and what effect they have on other components. The hope is to make 7psi +. The turbo is pretty big for a 125 so we will see. The E85 should help lol.

  2. #2
    Wanker MexicanBatman's Avatar
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    Awesome stuff

    Turbo from the 600cc not the 1000cc I take it

    What would be even more awesome if you could fab in a 450 engine

    Now that would be a blast to ride
    ..........

  3. #3
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    Thats fucking cool.
    I've been thinking about getting one of these for the commute to work.

  4. #4
    Wanker MexicanBatman's Avatar
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    Donít i had a Grom with a takegawa kit and pipe and tune

    A scooter is better and quicker

    And unless you are a tiny dude, a scooter is also less gay
    ..........

  5. #5
    Non Compos Mentos Gammaboy's Avatar
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    Saw two very small people commuting two up on a grom last night. Didn't look like a great idea...
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  6. #6
    Civic turbo + 100hp gas biscan's Avatar
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    Thanks for starting this. I was planning to start a thread soon

  7. #7
    "The bitches, are wet" Sketchy's Avatar
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    Updates?
    Quote Originally Posted by Dimi View Post
    80mm of penetration isn't bad, i wish i had that much.
    Quote Originally Posted by schnitzelburger View Post
    My entire working career pretty much consists of suckin dick and takin names.

    Sometimes im too busy to take names.

  8. #8
    Civic turbo + 100hp gas biscan's Avatar
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    We are trying to get flanges made for the turbo in stainless. I have made gaskets to suit and a friend is doing some tracing in CAD to get them laser cut.

    The ones i made on a friends plasma cutter were completely unusable. n.b. I had never used a plasma cutter before

  9. #9
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    Subscribed!
    Kebabhunter

  10. #10
    Nay sayer Mr Ed's Avatar
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    Is turboing a 125 a done thing? Ive never riden a turbo bike but i figure the power is pretty abrupt... smaller the engine the steeper the power curve right? Turbo 125cc must be pretty wild

    Fucking cool though
    #WHOTW award winner #blessed #susanalbumparty

  11. #11
    Civic turbo + 100hp gas biscan's Avatar
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    These make 8hp at the rear wheel stock Ed. I doubt it will get to 20hp.

    Should be a bit of fun to ride anyway !

  12. #12
    Civic turbo + 100hp gas biscan's Avatar
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    Some updates.

    A mate did the CAD tracing from a gasket i made for the housing.

    3d printed the flanges for test fit. Everything is spot on. Ready for laser cutting in stainless.
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  13. #13
    Registered User lukevl's Avatar
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    Lol I love you used a 3D printer to validate a DXF. Donít own a die grinder? 😉

  14. #14
    Civic turbo + 100hp gas biscan's Avatar
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    It is a whole lot cheaper to print another prototype than get 10mm stainless cut over and over if the holes are in the wrong spot !

    Also i needed a project for my printer

  15. #15
    Registered User lukevl's Avatar
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    Iím believing your second point! Top work carry on

  16. #16
    あなたの母親の肛門 Shifty's Avatar
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    Funny as.

    Also... be aware the front suspension compresses yeah? Need to allow for that.

  17. #17
    Civic turbo + 100hp gas biscan's Avatar
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    Funny you mention that Shifty. We had issues with the front guard hitting at full compression. Moved the intercooler to compensate and i have a full set of Ohlins suspension to go on as well. That should stiffen the front up substantially

  18. #18
    Civic turbo + 100hp gas biscan's Avatar
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    Foamy has been putting some serious hours in on the build of late.

    Really starting to come together.
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  19. #19
    Civic turbo + 100hp gas biscan's Avatar
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    Starting to work through some of the supporting mods now.

    Barnett clutch and HD springs installed
    Light weight flywheel - Saves nearly 1kg over stock
    30% larger oil pump
    Oil cooler fitted - Properly tight. 1mm between intercooler and 1mm between exhaust.
    Sorted the fittings for the -10 oil drain on the turbo.

    Still need to do
    Weld fitting for oil drain
    Make all the braided hoses for turbo feed, drain, oil cooler
    Fit GM Flex sensor
    Fit Mircrosquirt
    Fit Ohlins forks and rear shock.
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  20. #20
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    make with the choo-choo already beescan

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