Water Cooled Superlight.

Discussion in 'Supersport (1974-2007)' started by Pablo Pirate, Mar 19, 2012.

  1. Howdo!!

    Well sat on me dish after knee OP and bored..........so thought I would stick a quick dit on me Superlight :wink:

    Bit of background history......brought the bike over 12years ago and started tweeking! Lighter wheels, Billet calipers, FCRs, Hi comp pistons, Big bore, gas flow, balanced & blue printed and on and on the sickness went. Well I had a peach of an engine done by Chris at CJS and thought oh dear wanna bit more :rolleyes: Could have gotta 888,916.998 etc but had kinda bonded with the old 2Valver, therefore the intention was to try and keep the looks and heart of the bike but with STEROIDS added :biggrin: Got my hands on a damaged ST3 in 2007 and thought I would have a go at making it slightly quicker. Using a donar frame knocked up a so called test bike.
    ST3 Engine in Superlight frame - Copy.JPG
    After mucking about got it to this stage.
    Superlight_with_half_fairings_1600.jpg
    Quick session on the Dyno against a 944cc as a comparison, ST3 engine (Standard & PCIII) Ooooooooooooh my 20+Bhp extra (74lb of torque) and all the same feel as a 2Valve engine = Result.
    ST3 v 944 Dyno.jpg
    Know I just had to polish everything off to get that factory look and not something bodged together..........Ahhh the sickness.

    Well that's how it started back in 2007.

    Pablo

    ST3 Engine in Superlight frame - Copy.JPG

    Superlight_with_half_fairings_1600.jpg

    ST3 v 944 Dyno.jpg
     
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  2. Water-Cooled Superlight (Today)

    Howdo!!!!!

    Well that was how it all started and just to bring the ordeal up to date:

    The engine was sent to Chris at CJS to have the magic done. Pistal Hi-comp pistons, light weight flywheel, gasflowed, balanced and blue printed. End result 115Bhp n 77lb of torque, all held in place with12mm Ti engine bolts & breathing through a modded Sil-motor system.
    cjs st3 superlight.jpg
    Chassis - I ground of all those horrid tacked on bits at the end and got the headstock strengthened & painted black (Lost 1kg), Pro-Mach adjustable yokes held a set of re-worked 1098 forks & S4RS 4 pad radial calipers. BST's front (Ti spindle) and back, brembo master cylinders and braided lines with Speedymoto 53mm adjustable clip-ons. Adjustable rearsets.
    Superlight Dash.jpg
    Body work - Carbon seat unit from Kamna in Germany (Also acts as my crankcase breather expansion), Carbon DP headlight cowl, ETi fuelcell and soon to be carbon half fairings,carbon cockpit covers, carbon 1098 mudguard and SL rear.
    Water-Cooled Superlight.jpg
    Odds n Sods - 1 off Pro alloy rad n expansion tank, 1 off carbon belt covers, modded wiring harness, ST3 dash, 1 Off Magnecor HT leads, ST3 airbox with 1 off MWR air filter, Corse reed valve, Ballistic battery, ECU bracket, Moto science mirrors, modified headlight frame, mocal oil cooler, Samco hoses, Tech moto sprocket cover, tank support, alloy tank bracket, quick release fuel lines, 12volt socket.

    Think that covers most things???????

    Now for what I hope to get done:

    Fit Speedymoto water pump cover (In an attempt to tidy up the water cooled motor), Oberon clutch slave, Ti bolts (Why because they are so shiney!!!) Alter the headers and fit Lambda sensors (So I can remap each cylinder and remove the PCIII and suit the fuelling for the MWR) Get and fit my fairings and then decide on the colour to paint the bike.

    And finally is it going to be worth all the bother?????? We shall see, again only my opnion but currently to ride the bike still holds all that 2valve feel but with 30Bhp more and lots more torque. Could be argued that 80Bhp is enough........but we used to watch Black n White tellys!!! I've gone full 1080 HD :tongue:


    Pablo

    cjs st3 superlight.jpg

    Water-Cooled Superlight.jpg

    Superlight Dash.jpg
     
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  3. Thats really nice fella. Well done.
     
  4. This truely is a beauty Pablo, I've said it before but I like the way you've kept the overall look of a superlight, which is no mean feat with all the mods you've done. It's the attention to detail that impresses me the most, I applaud you fella :upyeah:
     
  5. Howdo!!

    Cheers gents :upyeah:

    Well got me Speedymoto pump cover today, collared by customs:mad: at a silly cost....never mind live n learn.
    speedymotoquatroo2pump.jpg
    Dropped the coolant and offered up the cover:eek: didn't fit!! On the inside there is only enough room for a 55mm impelor and the ST3 is 60mm - Improvise,overcome and adapt, oh and swear alot!!! Dropped the cover at a local machinist to see if he can mill it out.
    ST3 v Speedymoto (640x480).jpg
    So didn't really get what I wanted done and with all things Ducati more delay.....but ya gotta love em!!!

    Pablo

    speedymotoquatroo2pump.jpg

    ST3 v Speedymoto (640x480).jpg
     
  6. Very nice indeed. Remember seeing it at the TT a year or two back.

    Beefed up frame and updated front end are clearly well capable of handling the extra power, but what about the rear end?
    I was once warned (by someone with much more engineering knowledge and experience than me) not to put a 900SS swingarm in a special with quite a bit more horsepower, because it is already near it's limit in the 900.
    I'm not trying to send you down another river of upgrade pain and suffering, I just wondered.

    Steve
    (not Mr R)
     
  7. Howdo Steve.

    From Lincolnshire? Gotta be a top bloke! I'm originally from Stamford Lincs. Yep done a few more things to it since the TT, lost about another 10-15kg of the bike. As for the swingarm they did update on the fuel injection bike (However it's a nightmare trying to get one), mine is the earlier alloy version and I have had no issues so far (Kiss of death....some suffer from cracks at the pivot point, bending chain adjuster bolts (Older ones where 6mm then upgraded to 8mm). And seeing as it has a tendancy to sit on its back wheel.............................:upyeah: The actual swingarm is quite well braced but compared to more modern items it is classed as shall we say spindly. I've fitted Ti bolts at the Ohlins shock end but that's about it.
    Mr R and his spinnaker leathers lives just round the corner, I actually went to the TT with Steve that year - 2010.

    Cheers Pablo
     
  8. I can't wait to see your duke in the flesh Pablo, It's doudtful i will make it 2moz, So see you next week when i down for 3 days.
     
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  9. Howdo Steve.

    No problem mate, only day I'm not around is the 27th as in for another minor OP. I'll hop up the loft this weekend and get the cans down. If you need a place to crash give me a shout.

    Cheers Pablo
     
  10. How is Mr R btw ? Keep meaning to phone him!
    He told me last time i was down your looking after Beverley the bevel.
     
  11. Howdo!!!!!!!!!!!!!!!

    Got me Speedymoto cover back all milled out for £6.00 bargin.
    Milled Speedymoto cover (2) (640x480).jpg
    Her she is fitted :upyeah: Check the clearance and should be okay if not then I guess the impelor will make the bike even lighter. Will anodise silver I think???? Oh and remove excess gasket!
    Speedymoto Waterpump Cover. (640x480).jpg
    Taking of lighter here's me lightened belt tensioners, all counts :wink:
    Lightened Belt Tensioners (3) (640x480).jpg

    Cheers Pablo

    Milled Speedymoto cover (2) (640x480).jpg

    Speedymoto Waterpump Cover. (640x480).jpg

    Lightened Belt Tensioners (3) (640x480).jpg
     
  12. You've got it bad, hav'nt you? :biggrin:

    Top work, Mate!
     
  13. Well, if you lived under the ocean blue you might have some strange compulsions too!

    (Blimey, I'm a poet and I didn't noet)
     
  14. Excellent work Pablo!!!
     
  15. Hey Pabbers old chap...how on earth did you manage to get that marine diesel engine to look like a Ducati lump? :tongue:
     
  16. What kind of weight do you estimate for the built bike, Pablo?
     
  17. Howdo to you Pablo

    I'm a bit further North in the flat county, we talk a bit more Norf than Sarf at this end, but I won't hold it against you. How is Steve the old Essex export doin? Spinnaker leathers!!! I like that one, but would be wary of using it if he was within punching distance.

    Go steady on the weight saving mate, you will be gettin the dentist to drill your fillings out next, or will it be string vest style leathers?

    Bike looks good, apart from the colour obviously. You do know Yellow paint is heavier don't you? Ask Steve R, they used to put Lead in yellow paint.
     
  18. Howdo!!!

    You can say what you want to Steve he's that old he forgets 2 minutes later:wink: As for weight loss need to keep going!! Surprise those 998's and the like.

    Last time the bike was weighed I think it was around the 175kg mark, that's with a full tank of petrol (ETi holds more fuel than standard - fuel = 13.25kg) Knocked another couple kilo's of already. I think the standard bike was around the 200kg (wet) and made 73Bhp, people who think there bikes weigh what is printed in manuals (173 -180kg for a Superlight) or by manufactors claims will be sorely disappointed.

    Figaro how's it going with your bike?? Your target is a bit past mine so if you have any cool secrets I need to know I won't tell. Was it 150kg or 140kg?? That would be a rocket!!!!

    Aim is: To get under 170kg fully wet! Fnarr Fnarr!!! 120Bhp and 80lb of torque...............well as near as I can :smile: So need to shed another 3ish Kg ,5Bhp & 3lb of torque - minimal figures and some say you won't notice the difference but it keeps me from the looooooney bin......beep beep!!!!!

    Cheers Pablo
     
  19. Howdo!!!

    Well Postman Pat brought some more shiny stuff today:smile:
    Oberon Clutch Slave. (2) (480x640).jpg
    First up was a nice Oberon clutch slave.
    Oberon Clutch Slave. (640x480).jpg
    Followed up by flushing the cooling system with De-min and topping up some Engine Ice.
    Engine Ice (480x640).jpg
    And a few more shiny Ti bolts stuck on for good measure (From Flea Bay, lad on there knocking them out at a good price:wink:)
    Shiney!!!!! (480x640).jpg
    The sooner I get back to work the better!!!!! Ohhhhhh me credit card.

    Pablo

    Oberon Clutch Slave. (2) (480x640).jpg

    Oberon Clutch Slave. (640x480).jpg

    Engine Ice (480x640).jpg

    Shiney!!!!! (480x640).jpg
     
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  20. Howdo Again!!

    Pat also drop this off!
    IMG_0260 (640x480).jpg
    Tricolour LED Battery Monitor (Thanks for highlighting this 470Four :upyeah:)

    First up stuck me multimeter on the fuse box to check voltage via the ignition switch.
    Then I used the hole in the left hand cockpit cover, this is where the twiddly knob for the trip sits (As I've fitted the ST3 Dash it was empty).
    Battery LED. (480x640).jpg
    Then wired the red wire on to the fuse box (Top of the fuse box - Engine stop. Pain in the butt getting the fuse holder outta the box, soldered and heat shrinked the connection).
    I then terminated the black wire to earth.
    Switched on and the LED cycles through proving all three lights.

    With the engine off LED is Amber (12.45volts).

    Cheers Pablo
    Battery LED (Ignition on) (640x480).jpg
    Start the bike and a second later the LED goes Green (13.2volts charging) which is nice:biggrin:
    Battery LED (Bike Running). (640x480).jpg
    I asked them to set the Red naughty LED to 14.2volts, just down to the fact I'm running a Lifepo4 battery and they don't like charging above 14.4volts for long periods.

    Battery LED (Ignition on) (640x480).jpg

    Battery LED (Bike Running). (640x480).jpg

    Battery LED. (480x640).jpg

    IMG_0260 (640x480).jpg
     
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