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After installing 300 cc kit and removing secondary throttle plate I got unstable idle. Sometimes going as high as 3000 rpm. I went to inspection and the problem was apparently related to how ECU controls idle along with secondary throttle sensor. I've removed spring from throttle body as suggested by @tooter and problem has gone! Now stable idle and crisp gear shifts.
PS there is one more interesting dyno run (as I was double checking my AFR mapping)
knobby off-road tyres new Dunlop D952) - pink on the graph
dual sport tyres (wear stock Dunlop D605) - red & blue on the graph
As you can see difference is quite dramatic. I think if I dyno the bike on road types the power will be close to 27hp.
Hey folks. I have new portion of dyno runs. I made full custom exhaust with megabomb style header and also wanted to try MCM at the intake cam.
First run is new exhaust compared my previous set up (300cc AHL kit, KDX snorkel, no secondary throttle, modified stock muffler where I replaced end "straw" pipe with 2.5 cm pipe)
25 hp vs 26.8 hp. Not bad!
I decided to see what will happen with open airbox (lidless). 28.5 hp! See pink and green runs below:
I tried intake cam mod (partial MCM) on top of it, but reverted back to stock cam timing. Cam mod gave slight edge in torque below 6500 rpm, but can't maintain it after. So with intake cam mod bike makes 27-27.5 hp at 7500 compared to 28.5 with stock cam timing.
There is possibility to unlock more power with the same hardware, but it will require tuning ignition. On the graphs below it's clear that torque drops from the cliff after magic 7500 rpm. I believe this is what Kawasaki has done to detune bike to meet emissions. With proper ECU (apitech?) it should be possible to get 30+ hp at 9000-9500 rpm.
Hey folks. I have new portion of dyno runs. I made full custom exhaust with megabomb style header and also wanted to try MCM at the intake cam.
First run is new exhaust compared my previous set up (300cc AHL kit, KDX snorkel, no secondary throttle, modified stock muffler where I replaced end "straw" pipe with 2.5 cm pipe)
25 hp vs 26.8 hp. Not bad!
I decided to see what will happen with open airbox (lidless). 28.5 hp! See pink and green runs below:
I tried intake cam mod (partial MCM) on top of it, but reverted back to stock cam timing. Cam mod gave slight edge in torque below 6500 rpm, but can't maintain it after. So with intake cam mod bike makes 27-27.5 hp at 7500 compared to 28.5 with stock cam timing.
There is possibility to unlock more power with the same hardware, but it will require tuning ignition. On the graphs below it's clear that torque drops from the cliff after magic 7500 rpm. I believe this is what Kawasaki has done to detune bike to meet emissions. With proper ECU (apitech?) it should be possible to get 30+ hp at 9000-9500 rpm.
Thanks for making the video. The exhaust looks great, did a local shop make it for you or were you able to purchase it from an Indonesian website?
I made it at respected workshop where I knew the quality will be good. And I had specific request - megabomb, heat shield, o2 sensor mount, not too loud, weight under 3kg.
It's possible to order online in other places, but I'm not sure about quality and noise level.
And it didn't tick all my boxes.
I installed uncorked japanese oem Kawasaki ECU. The top end power is night and day. Power all way to 10000rpm. According to my butt dyno should be for sure 30+hp. My bet is 33-35 hp. I will run dyno in a week or two.
While experimenting with ECUs I found several promising options with different part numbers. So now I have 2 extra uncorked ECUs. If someone interested - $300 per pcs. It's hard to get them, so be fast if you want it.
