Upgrading a 907ie

[JoKing]

Yes, thats me :-)

But the engine-switch was not perfect, due to my lack of skill and knowledge.

There is one big issue:
The ST3-engine is attached at only 3 points to the frame.
The 907-Frame is too weak at the upper forward engine mount.
This is what follows:


So I disassambled the whole thing. I am going to rebuild it with improved mounts...
Status:


Disassembly in living room:

[Tamburinifan]

Sorry to hear.

Seems you have to be registred to see your links.
Are there just pics there or full rebuild story?
Pics elsewhere?

[JoKing]

Just some pics there... I will try to upload the pics here...
I only made some posts on Motor-Talk, thats all what exists. Not many pictures on my own computer as well.
But there will be a better documentation this time.
All I can say about that:
The ST3 engine is the most easy way to improve the performance of a 907.
It is not that complicated.
It cant be complicated.
I did it


/edit: wow... the pics are....biiiig... next time i`ll shrink them...

[Tamburinifan]

Most easy way, hmmm, what about dashboard, ECU & wiring?
Any troubles w alignment, chain-sprockets f e?
And btw, how many Watts fr ST3 alternator?

I did it

AND f sharing!

All info you`d like to share very appreciated,
I`ve had this mod in my head sinceI saw the MotorTalk thread...
Start a new thread w lotsa pics and give us the power numbers, bet more would be interested!

[JoKing]

Well, some days passed since i did the swap, so i do not remember the exact values.
Chain alignment is no problem. You can solve this by using the right sprocket. The airbox has to be modified. The cooling system is easy to adapt.

The dashboard... yes. I put the electrical rev-counter-drive into the original housing, but I do not get it working. Oil-Temp is shown in the water-temp. scale (switch by switch...^^).

The Engine-housing has to be milled a bit at the rear lower engine mount.

The actual power-output is maybe 110HP or so at the wheel. Maybe less. Equal to a 2006 Yamaha R6 on the straight. Enough to get the speedo over 240 km/h. In 5th Gear. And then you switch to 6th gear and it goes on...

I am very tall, 2,12m. So my weight is 110kg. With my girlfriend on the back seat (alltogether 175kg plus), I overtook a fellow on his really good running 907, while he was overtaking a car with throttles full open. He did not know about my engine. You should have seen his face at the next stop.

But, I have to say:
I did many things trial by error. I had gooood luck, that it (nearly) all worked well out.
I needed 1,5 years. Although it is easy for a crack.

[persempre907]

I am very tall, 2,12m. So my weight is 110kg. With my girlfriend on the back seat (alltogether 175kg plus), I overtook a fellow on his really good running 907, while he was overtaking a car with throttles full open. He did not know about my engine. You should have seen his face at the next stop.

I needed 1,5 years. Although it is easy for a crack.

Good work, compliments.
I have always been told the ST3's engine is a great one.
Ciao

[ducapaso]

I have always been told the ST3's engine is a great one.

True!!!

[JoKing]

Current Status:



Frame and fairing will be handed over to the paintshop tomorrow.

Graham from "The Image Works [sales@the-image-works.co.uk]" made all decals. I got them from ebay. Really good stuff. The frame-decal he made for me free of charge.
He owned a 750 Paso some years ago...

This is his bike, someone who knows him?

[Tamburinifan]

Have you made the reinforced engine mount yet?
And, was that the only issue, any small ones?

[JoKing]

Yes, the welding has been done.
Only small reinforcements on the engine mount, because i did not want it to have any effect on the frame itself.
The frame should take the loads without effort...

[Tamburinifan]

Did you just reinforce the original ones?
Pics?

[englishstiv]

I am beginning to wonder whether we should all check those engine mounts on our bikes as I had one fractured and one snapped on mine, found after I stripped down the bike, I also purchased two off ebay and when stripped of paint one had a hairline fracture in the same place. I have just re welded mine and packed it with extra weld iron.

Now I know my bike has tumbled down the road a few times with previous owners and the spares off ebay were probably a trashed bike however it may be worth a check as it is a simple repair and can be done with the engine in situ and the bracket off the bike.

If push comes to shove then I am sure a simple billet replacement part could be fabricated and relatively inexpensively too?

[paso750]

JoKing, three questions.

- what did the TÜV say about the engine conversion ?
- why did you have the frame painted not powder coated. (I planned to have that done, too a few years back but painting would`ve easily cost €350 while powdercoating incl all the small bits like center and sidestand etc did cost €80.
- the frame decal you mentioned, which one is it and what did you do about the "Typenschild" which is gone after sanding or mediablasting ?

Actually that were 4 questions.

G.

[JoKing]

- what did the TÜV say about the engine conversion?
--> What he actually said? "Looks great"! A good one, really. At first, he had some issues with the US-American engine-number. But i convinced him, that the european engines are similar. The exhausts are ST2 - Marving with catalytic converter. So he did not ask for the "Abgas-Werte". The "AU-Werte" were much better than original. Brakes are equal to more powerful bikes, so no issue here. The "Ultimap"-ECU he did not like, but i ensured him, that i had a german mapping on it.... The trick is, to take the complete drive chain out of the ST (including airbox, etc.), and put it into the 907. So you can take all values from the ST.

- why did you have the frame painted not powder coated. (I planned to have that done, too a few years back but painting would`ve easily cost €350 while powdercoating incl all the small bits like center and sidestand etc did cost €80.
--> The paint will be 150€ for the whole frame. Sidestand will be a new one, I hope. There are some points, why I did not powdercoat. 1. You do not see any corrosion below the surface. When you see it, it is way too late. 2. The repair of paint is easy. Try to repair the coat... 3. Try to get the coat of the frame in some years. It is near to not possible. 4., and I am not going to translate, sorry, I can`t: "Bei einem Werkstoff, der als Pulver elektrostatisch aufgetragen wird, durch äußere Wärmeeinwirkung angeschmolzen wird, ist noch lange nicht sichergestellt, dass dieser durchgeschmolzen war und alle Poren sich geschlossen haben. Dies besonders hinsichtlich unterschiedlicher Materialdicken und daraus differierenden Werkstofftemperaturen. Das Verfahren wurde einmal entwickelt, um Drahtteile aus gleichdickem Werkstoff ohne Tauchbad trotzdem möglichst verlustfrei zu beschichten.Fragt euren Pulver-Beschichter nach dem technischen Datenblatt und der Zulassung des Werkstoff für Außenanwendung, dann fallen schon mal 70% der Materialien weg, übrig bleiben die sündhaft teuren." 5.: I don`t understand all the coating-hype....

- the frame decal you mentioned, which one is it and what did you do about the "Typenschild" which is gone after sanding or mediablasting ?
-->Maybe I can upload a pic of the decal this evening. The "Typenschild" on both sides of the frame i disassambled, before sandblasting.

[JoKing]

Double post