GL1100 with GL1200 LTD EFI conversion

[theailer]

Alright, I do know i can just change the idle via the idle set screw instead of trying to hold it at 2000rpm with the throttle wire between my fingers =) but yesterday my mind were elsewhere

Today I sorted most of my issues.

Last year I bought a whole bundle of intake runners and plenums which resulted in me putting on the prettiest intake runners on the bike without realizing there's vacuum port on the backside on one of them. It is now blocked(guess it is used for balancing the banks?). Well, balanced the banks and now I'm back to using one VE table
Had fueling issues, when motor is idling and at operating temp it would lean out to the point of stopping and I can hear the fuel pump running at full tilt(it is pwm controlled and should definitely not run when motor is not requiring fuel).
Faffed around with the filter and petcock, ran a fuel line from one of the ports on the fuel rail back to the tank and had good flow.
Tried get it to temp again and it ran lean when coolant reached 90-100C.
Off with the filter and fuel hoses and noticed that the fuel hose was resting at the right motor mount(the chromed triangle) bolt and I guess the fuel was getting so hot the pump couldn't pump it around. Replaced and rerouted the fuel hose along the same route the hose for the radiator overflow takes. And presto, all good. Well almost anyway.
I now know why the motor was pulled from it's frame all those years ago, the stator needs replacing.....
Pretty sure I measured the resistance between the phases this winter but doesn't help much now. I've ordered a new stator, a electrosport esg 165. So I'm really looking forward to pulling the motor again

Road trials tomorrow, battery will last a while and the stator is just barely charging.

IMG_2970.jpeg

[Rednaxs60]

Good looking ride. Good luck with the road trials.

[theailer]

Thanks.
Sometimes it's the small stuff, the fuse between rectifier/regulator and battery had blown. New fuse is cheaper and easier to replace than the stator

I do still have an issue with the fuel pump getting hot, around 50C, which apparently is enough for vapor lock. The pump currently sits on top of the frame where the center stand once was. I've enveloped it in heat shielding and rerouted the hoses once again. It lasts a bit longer, especially now in the evening but I can feel it getting leaner and leaner the longer I drive. I'll look into either getting an in tank pump or try cool the existing one by either repositioning it or add some fuel cooler to the fuel hoses. But tuning is progressing in betweemn. I've even been on the asphalt road a couple of times this evening. Will hook the ECU to the signal from the pressure sensor in order to keep track of the vapor lock so I won't tune that part for nothing.

[Rat]

This whole thread is full of technical terms that are new to me … here's another one …

"Faffed around with the filter and petcock"

Gord

[theailer]

Haha

[theailer]

Got really fed up with that external fuel pump so I did what every man would have done from the start
Installed a pump inside the tank instead. If this fails in the same way I'll go ballistic.

IMG_2982.jpeg

[Rednaxs60]

I remember this from socrace's build. He too used an internal tank fuel pump. The issue with external fuel pumps is it must be rated for external operation, ergo, not just any fuel pump will do. One of the criteria I look for.

Good looking wiring setup.

Be interesting to hear how your solution works.

[Rednaxs60]

If you are looking for a compact fuel filter, recommend a fuel filter for a 2014 Can-AM Spyder. It's for a 1300 engine so should work well for a 1200 GW engine.

Forgot to ask, what fuel system pressure are you using?

[theailer]

Yeah, the old pump was an external but I guess I got the short straw at amazon on that one.
As it would happen I had a complete in tank pump assembly for my Skoda that I retrofitted to the gold wing instead.
Initially I was pressing for 3bars, but unfortunately I managed to short out the mosfet on the returnless pump controller.
So instead of waiting to tune and ride the bike I put the old gl1200 fuel pressure regulator back and used the petcock as the return. Seems to work rather nicely, I set the software to 2.5bars since that would seem to be in the ballpark for the original fuel system. Bike feels much better now. A VE table is starting to shape up, I'm logging in the ECU and then download it to the laptop and checking the fueling on each pass.
If it looks weird it is because I've only made two passes on my gravel road at like 30kmh so only tuned a few cells. more tuning tomorrow!

Screenshot 2025-06-13 at 21.21.47.png

[Rednaxs60]

Fuel rail pressure - there is a fuel rail pressure port on the right side fuel rail:

Fuel Pressure Gauge Fitting Installed.JPG

. Use this connection to install a fuel pressure gauge to monitor fuel rail pressure. This will let you calibrate the engine tune setting. Once you confirm the fuel rail pressure, derate, or not, the fuel injector flow rate to match.

If you have installed the 1200 FI FPR, it is rated at 28 (1.9 BAR) to 32 (2.2 BAR) PSI actual during engine operation, KEY ON engine started, you will have to derate the fuel injector flow rate in the tuning software. Recommend splitting the difference to 30 (2.0 BAR) PSI. Flow rate should be around 283 cc/min. Confirm fuel rail pressure first then do a derating of the fuel injector. The FPR should indicate approximately 36 PSI, KEY ON engine not started.

Fuel injector size not very relevant unless too large or too small. The ECU will control the opening/closing of the fuel injector so that the correct amount of fuel is injected.

Cheers

[Rednaxs60]

Browsing on-line resources and found some interesting threads on the Speeduino forum regarding fuel temp, pumps and such. Interesting read. There are posts that redirect you to other threads that are related. Thread to start with: https://speeduino.com/forum/viewtopic.php?t=6371
https://speeduino.com/forum/viewtopic.php?t=6433

[theailer]

Been doing longer and longer runs. Last run was around 30kilometers.
Tune is far from perfect but it is getting there, a real boost to the ego when everything starts working out. Been quite annoyed at my old motor for smoking and drinking copious amounts of oil so this feels like quite the accomplishment.

[Rednaxs60]

Excellent! I had the same feeling last year when I started road trials. Will probably have the same again very soon.