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Old April 8th, 2018, 07:55 AM   #1
greg737
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Refurbishing and upgrading my '05 fuel injection project...

It's pretty quite around here these days.

I don't know how much enthusiasm there is for anything related to the "Pre-Gen" year models, but I'm still enjoying mine after 13 years of ownership.

Posting here today because I'm going to be refurbishing the bike a bit and upgrading my do-it-yourself fuel injection system. I did the fuel injection conversion about 10 years ago. My EX250 was my first attempt at something like that and while it turned out well and the bike runs great to this day there's a lot about the overall qualities and features of the job I did that now (with more knowledge and experience) I know could be better.

So I can just do my work quietly without posting anything, or I could do some pictures and words.
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Old April 8th, 2018, 02:49 PM   #2
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I vote pictures and words!
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Old April 8th, 2018, 06:11 PM   #3
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I'll be watching and taking notes.
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Old April 8th, 2018, 11:30 PM   #4
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I definitely looking forward for more info on the use of the map sensor array.
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Old April 9th, 2018, 06:59 AM   #5
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Please post progress! I’m using your previous threads as guidance for my 2003 pre-gen EFI project with Microsquirt. Gonna use a plenum to even out pulses and MAF sensor before throttle-body to get more accurate mass measurements.

Also stuffing 2007 EX500 into my other 2003 pre-gen frame for fun track toy. Going to try carbs first to get going quickly. Then Microsquirt it if packaging too tight for carbs.
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Old October 30th, 2019, 01:40 PM   #6
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Really curious to see what improvements youd make. I thought i had found your thread making it but i can't seem to find it.
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Old October 30th, 2019, 04:31 PM   #7
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Can’t wait to see the progress.
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Old October 30th, 2019, 06:26 PM   #8
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Well, here's the way it eventually happened: I did all of the Fuel Injection system refurbishing and updating of the bike just as I'd intended to do.

-re-wired entire FI portion of bike's wiring harness (better, neater, more logical and functional)
-replaced the Microsquirt V2 ECU I used in the original FI build-up with the new and improved Microsquirt V3
-re-installed the bike's original airbox (ditched the K&N 0990 filter pod which never performed as well as the original airbox)
-built and installed a two-MAP-sensor Arduino Nano-controlled Intake Air pressure sensor circuit (one MAP sensor in each cylinder intake)
-relocated battery-box portion of airbox to make room for FI fuel pump

Plus (not FI related items):
-removed the bike's original shunt-type Regulator/Rectifier and installed a MOSFET-type Regulator/Rectifier
-replaced clutch with 2009 Next-Gen EX250 unit (new friction plates too)
-replaced oil screen cover with Next-Gen EX250 "deep sump" cover/drain
-re-covered the seat with new cover (better design, carbon-weave look)
-replaced all lights with LED (headlight, turn signals, brakes, instrument)
-swapped original turn signal flasher for an LED signal flasher
-got new tires installed


... but while I was doing the work I just wasn't in the mood to go the extra mile of documenting the work.

I was focused on getting the bike done so my daughter could start riding it. So I just got the work done without wasting any time. My daughter has been on the EX250 for over a year now. She doesn't ride it much, it's just something we occasionally do together but she enjoys it (it's good Daddy-Daughter time, which I really value).

Here's a picture of my daughter on the EX250 just after I got most of the work done.


Last futzed with by greg737; October 30th, 2019 at 07:39 PM.
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Old October 30th, 2019, 06:27 PM   #9
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Here's a picture of the re-covered seat:

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Old October 30th, 2019, 06:33 PM   #10
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Getting all the Fuel Injection items to fit behind the newly re-installed Airbox required moving the Coolant Overflow Reservoir slightly forward.

Here are a few pictures of the re-located Coolant Overflow Reservoir:





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Old October 30th, 2019, 06:38 PM   #11
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I had to cut off and re-orient the Battery Tray portion of the Airbox.

This had to be done to provide enough room to locate the Honda TRX500 Rancher ATV Fuel Pump next to the Battery.

Here are a few pictures of the relocation and arrangement of things:







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Old October 30th, 2019, 06:49 PM   #12
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I replaced my 2005 EX250's original clutch assembly with the clutch assembly from a 2009 Next-Gen EX250.

Here's a few pics of the work, showing that the 2009 Next-Gen clutch assembly is a bit lighter than the 2005 Pre-Gen clutch assembly:

Pre-Gen clutch assembly (plus all the bolts, springs, washers and nuts)


Next-Gen clutch assembly (plus all the bolts, springs, washers and nuts)


If you're going to swap a Pre-Gen clutch assembly for a Next-Gen clutch assembly you have to also get the correct "pusher" because the Next-Gen item is shorter than the Pre-Gen (if you try to use a Next-Gen clutch with a Pre-Gen "pusher" you won't have enough clutch-lever movement to work the clutch)
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Old October 30th, 2019, 06:57 PM   #13
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Here's a picture of the bottom of the bike.

This picture shows the location of the Bosch 5-wire Wide-Band Oxygen Sensor.

Also shown in this picture is the installation of a Next-Gen "deep sump" oil screen cover. The "deep sump" oil screen cover is a nice-to-have item because it increases the amount of oil the engine can hold and it also makes oil changes a little bit easier.

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Old October 30th, 2019, 07:01 PM   #14
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Here's the nice, modern, MOSFET-type Regulator/Rectifier that I installed in place of the old-school Shunt-type R/R

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Old October 30th, 2019, 07:07 PM   #15
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I replaced all the bike's lights with LED (headlight, turn signals, brakes, instrument panel lights).

When you replace the bike's turn signals with LEDs you have to replace the bike's original turn signal flasher with one that is specifically designed to work with LEDs.

Here's a picture that shows the installed LED turn signal flasher (just above and to the left of the fuse box)

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Old October 30th, 2019, 07:28 PM   #16
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The Arduino Nano-controlled 2-Manifold Absolute Pressure Sensor circuit was a home-made effort. I didn't design it, got the idea and a lot of help from a guy in Germany.

Small, high-revving pistons of small motorcycle engines (like the EX250) produce really jumpy-jagged-messy Manifold Absolute Pressure signals that aren't very good for input to an ECU.

This circuit monitors each of the two cylinders individually. On a millisecond-by-millisecond basis the circuit determines which of the two cylinders is producing a lower signal (i.e. pulling more vacuum) and it send only that signal onward to the Microsquirt ECU.

This discrimination smooths out the MAP signal for the Microsquirt ECU.

In this picture:
-the 2 rounded black plastic items are the MAP sensors
-the green item is the Arduino Nano
-the red item is a Digital-to-Analog converter
-the brown item is just a piece of basic circuit board to hold/connect the items (lots of wire and soldering)





I put the whole thing into a weather-proof plastic project box.





Not shown in these pictures are the rubber hoses that connect the MAP sensors to ports on the throttle body.
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Old October 31st, 2019, 03:46 PM   #17
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Great work, Greg!!! Thanks for sharing with us.

I'm playing with an Arduino for a car project myself. With an Arduino and a 3D printer, there's all kinds of opportunities in cars/bikes/anything.
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Old October 31st, 2019, 08:48 PM   #18
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Awesome projects, thanks for sharing.. Cannot wait for my gaskets to come to start the clutch and the oil pan projects. EFI is over my head for me though
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Old November 1st, 2019, 12:52 AM   #19
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Neat project! I'll be reading more!

I noticed the rather large exhaust. Just curious, which brand, or what other bike is it from? Looking to update my GFs 07.
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Old November 1st, 2019, 04:02 AM   #20
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