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...because every day is MotoGP day when you own a CBR 125r...
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PostPosted: Thu Jan 15, 2015 2:01 pm 
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Racing ECU (!!)
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Joined: Sun Mar 23, 2014 9:21 pm
Posts: 535
Location: Parksville, BC, Canada
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I was just digging through a ton of digital pics that were taken throughout the development cycle (<=see what I did there :laugh: ) of the CBR 125r. There's a lot of neat stuff in there so I thought I'd start posting up the odd one and explaining (when needed) the story behind them.

Let's start off with some recent stuff....



Direct Port Nitrous Injection

One of my recent favs, the direct port nitrous injector installation worked out really well. I love the blue fittings and the stainless braided lines :top: The nozzle is precisely installed such that it blows high pressure liquid nitrous (soon to be vapor) directly towards the roof of the throttle body and directly at the atomized fuel spray from the fuel injector. It should result in a nice blend of atomized fuel/nitrous...

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The completed throttle body. The location was chosen to meet several design criteria. Atomization of nitrous/fuel is key, direct injection is another, the last is easy access to the nitrous jet without removing any body parts. This helps facilitate very fast roadside nitrous jet changes during the testing/eval process.

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Engine guts during a complete overhaul. This ended up being required after beta testing several aftermarket camshafts....

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A nice close-up during one of the overhauls. This is what's inside your engine when you split the case.

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One of my favorites - this is the entire 6-Speed transmission with my DVR remote to illustrate just how small the transmission really is :top:

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My development cycle on the Dyno during a development cycle :laugh:

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More of the same...A LOT of R&D goes into our products. This way we know for a fact what we are selling and exactly what it will do for the end user (that's you :top: )

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Like the shot with the DVR remote this my development cycle next to it's big brother, the CBR 600RR. There's an interesting story behind this picture. The CBR 600 RR is a 2008 - the same year as my bike :smile: I had just installed the new Metzeler Interac M5 tires on the bike and had completed the suspension work only a week before so I had some racing time on the new setup and it was....unreal.

I was bragging about the new handling to a friend (with the CBR600 RR) and so we decided to hit the 'track'. About 20 minutes after this picture was taken I had completely cleaned his clock on a 3 KM stretch of twisties with short straights. It was one of my fastest rides and I nailed the last corner at a speed that was insane (a reducing radius banked corner). I'll never forget that last corner, the bank increases as the radius reduces :ohmy: and I hit it hard. I actually felt something flex in the bike.... :blink: :unsure: Anyway, I was far enough in front of him that I was able to pull off at a rest stop, take off my helmet and get off the bike!! When my friend showed up he could not believe the run I pulled off and he insisted, right there, that he take my bike back to the beginning of the run and do it himself. Which he did, and ever since then he's mentioned the handling of the bike to everyone who raises an eyebrow when we ride in a pack so that they don't discount the 'little' bike :cool:

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Our exclusive TrueHD Clutch Springs. These came about through our R&D when we determined that the OE and the aftermarket 'HD' clutch springs still resulted in slipping clutches. The more power we added to the bike, the more the clutch slipped. Because there are none available anywhere, we made our own and offered them up for sale! :top: The most common reported side affect of installing the TrueHD clutch springs? The front wheel lifts up off the ground when shifting into second and third :top:

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Another outgrowth of our R&D is the world's first Carbon Fiber Clutch kit for the CBR125r. I always knew that the TrueHD clutch springs were only half the battle. What we really needed was to address the other side of the clutch equation, the friction disks themselves. Simply put, the more power we developed and put into the bike, the more the clutch continued to take a beating :laugh: The TrueHD springs got us to the point where the clutch would lock well but only for about 3 months of really hard racing. At that point the clutch frictions would always show signs of wear and begin the decline once more. So we bought time with the TrueHD springs but we still had more work to do :top:

To make a long story short, we came up with a new Carbon Fiber Clutch Kit. With 433% more 'sticktion', and an ability to handle high heat, this turned out to be the answer to the friction side of the equation. This dove-tailed nicely with our R&D efforts on the TrueHD springs (which have somewhere between 300-400% more clamping power on their own). I think we've finally finished off with the clutch side of the bike for the foreseeable future :top: This became our new Racing Clutch Kit and it works very well on the street. Suffice to say, we have yet to look at our clutch and it's been about 6 months now and the bike is continually increasing in power....with much more to come this year!

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An early shot during the Port Alberni toy run. As I recall, I was riding in a pack of about 1200 bikes :top: It was a wild ride with a wild weekend to follow :top:

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Earlier I mentioned an engine overhaul being required due to using 3rd party camshafts....this led to the creation of our own custom camshaft, one that lasts as long as the OE Honda cam. This was no small feat but we've been running on it ever since :top: It's got a lot of lift as you can see from the picture showing how close the lobes are to the carrier....

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2014 was a good year for the CBR 125r :top: Lot's of development resulting in lots of high quality products for the general community. Reports continue to come in from riders all over the world attesting to the results and without exception, everyone has been very pleased, which, for me, is the real reward :top:

Ahh! I almost forgot the most important one of all which was actually developed in late '13 - the Performance Pack. Comprised of new custom components and married with pre-existing 'tried 'n true' mods it's the single best bang for the buck that a rider can install. Coupled with HD installation videos to give you a step-by-step guide it's been very popular, and rightly so. The Performance Pack was developed through racing against a 200cc bike. In the end, we negated a 75cc advantage with the Performance Pack alone. The 200cc bike was thoroughly trounced on the straights and on the corners to the extent that it was promptly sold off by the owner :ohmy:

Up until this point, riders had to resort to very expensive means to get that kind of performance, the most common being a $700 bore kit which brings the bike out to 166 or 170 cc's. Point being, the Performance Pack, at $149.95, negated a 75cc advantage over the 200cc bike we used to race against. :top:

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There's a lot more to the Performance Pack then that, but you can find all the information on it in the http://www.cbr125world.com/store/product_info.php/products_id/31 Store.

_________________
Best & Thanks!
Marvin Miller
cbr125world Store

...because every day is MotoGP day when you own a CBR 125r...


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PostPosted: Fri Jan 16, 2015 4:23 pm 
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Racing ECU (!!)
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Joined: Sun Mar 23, 2014 9:21 pm
Posts: 535
Location: Parksville, BC, Canada
Canada
An early install of the digital gear position indicator. It was later changed over to a red LED to more properly fit the bike's color scheme. Once the mounting bracket was figured out it worked really well.

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Getting to the point where we had a good understanding of what it takes to make a great camshaft required a lot of testing, in the case of the 3rd party aftermarket cams it unfortunately became destructive testing.

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Those aftermarket camshafts resulted in complete engine failure but, after a lot of work, we came up with this;

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Our first racing camshaft :top: It's still in use to this day. With our new racing ECU we hit a real 12,500 RPM all the time with this camshaft - which is what we were originally after :top: We just had to get rid of the rev limiter first :laugh:

Prior to installation, checking the piston-to-valve clearance

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That's dum dum! (no kidding!)

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We machine our own cylinders in-house for better ring seating and faster break-in, among other things, here's an example of a coarse finish we tried.

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A new piston & pin before installation

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Sometimes the bike interferes with real life and it has to take a back seat :laugh:

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New valve seals and if I recall correctly HD springs

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A freshly re-built engine ready to install. This one with all new bearings and a bunch of other stuff;

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Testing out Dyna Beads
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Testing out the new Metzeler Interac M7 RR's developed with Guy Martin on the Isle of Man TT circuit
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Freshly installed :top: These new M7 RR's were easier then the M5's as they have less belts in them. They are a much softer tire and it's readily noticeable how much more they 'dig in'. I think I'm going to raise the tire pressures a bit.

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This is one main reason why the M5's are so hard to install. They are Z-Rated and once you remove all the rubber you can see the amount of belts in them. There's a reason why they are stiff and why they perform so well.
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Checking out the gas tank coating two years after application. That worked out really well :top:
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A shot from long ago - doing a tail tidy :top:
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Back on the Dyno at some point
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Looking at the crankshaft position sensor output during ECU development to troubleshoot an issue
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_________________
Best & Thanks!
Marvin Miller
cbr125world Store

...because every day is MotoGP day when you own a CBR 125r...


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PostPosted: Wed Feb 11, 2015 11:13 am 
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Location: Parksville, BC, Canada
Canada
Nitrous bottles installed....


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_________________
Best & Thanks!
Marvin Miller
cbr125world Store

...because every day is MotoGP day when you own a CBR 125r...
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PostPosted: Wed Feb 11, 2015 1:58 pm 
Wow. Fantastic summary Marvin. Lots of work and impressive progress. I have to say that I love that camshaft. Hopefully at some point you'll be able to mass produce them along with your programmable ECU. If I still had my 2009 CBR125R I'd spring for that combination right away.

Mike


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PostPosted: Sun Dec 27, 2015 6:28 pm 
Beautiful bike! I sure wish I was as mechanically inclined as you to do work like that on my own bike. Sad to say, but my old man never taught me anything about vehicles :(

Out of curiosity, how did you do that digital gear position indicator modification? I wish my dash could have that. Right now, they are sporting blue LED lights instead of the common white incandescent bulbs and I have modified the front turn signals to be shorter. But your bike is amazing!!!


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PostPosted: Sun Dec 27, 2015 6:57 pm 
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Joined: Sun Mar 23, 2014 9:21 pm
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Location: Parksville, BC, Canada
Canada
Thanks!

The LED gear position indicator was something I did a few years back. I picked up an inexpensive gear position indicator off e-bay from China and then made a custom aluminum bracket for the sensors down at the shift lever.

The way it worked was that there were two sensors that were activated by a magnet. So you put one sensor on the downshift side of the shift levers travel and one on the upshift side. You then epoxy the little magnet half-way between the two on the gear lever.

When you upshift the magnet moves towards the upshift sensor and when you downshift the magnet moves towards the downshift sensor. It worked quite well once it was adjusted properly. For installation in the speedometer I cut open the display unit and then cut a more/less exact size hole in the speedometer for it. This was a bit tricky but in the end it looked pretty good and it worked very well.

From a fabrication standpoint it was a bit of work. Not for everyone. But if a person takes their time and like to fabricate things it works quite well. I later swapped out the blue LED for a red LEd indicator - this looked a lot better given the bike is red and the dash lights were original.

On the other hand, the gear position indicator was inexpensive, about $20 so even if I never installed it it would not have been the end of the world.

_________________
Best & Thanks!
Marvin Miller
cbr125world Store

...because every day is MotoGP day when you own a CBR 125r...


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PostPosted: Sun Dec 27, 2015 7:53 pm 
very kewl. I'll have to look into that. Thanks!


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