Fuel System    

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Updated: 2005-02-05

      
Gixxer original fuelrail (55590 byte)  Gixxer fuelrail plugs (55317 byte)
Gixxer fuelrail inlet (59585 byte)  gixxer fuelrail threaded end and plugs (64331 byte)
Gixxer Fuelrail
fuelrail 1.jpg (57807 byte) fuelrail 2.jpg (53550 byte) fuelrail 3.jpg (47787 byte)
New Fuelrail
fuelrail brackets closeup.jpg (58674 byte)
Fuelrail Brackets closeup
rail and injectors 1.jpg (54063 byte) rail and injectors 2.jpg (61024 byte)
Fuelrail and Injectors
rail on tb.jpg (64230 byte)
Fuelrail on throttles
MSD 2225 (3051 byte)  MSD PN2225 flowchart (13762 byte)
MSD PN2225 / Flowchart
bosch fuel pump (22369 byte)  bosch 254909 flowchart (63346 byte)
Bosch 254909 / Flowchart
fuel pressure regulator (66052 byte)  fuel filter Mahle KL5 (63036 byte)
FPR / Fuel Filter
Russell 90 elbow Endura hose end (11703 byte)
Russel Endura fitting
 
 
Related Links 
Drawings 
OBX Racing Sports
MSD
HydroScand
Mekonomen
Russell Performance Plumming
JEGīs High Performance
NBM Hydrolics
Indanc UK
KTS American Parts
C&P USA Parts
 
 

As I altered the distance between the throttles, I can’t use the original fuel rail so I am making a new rail in stainless steel. It has slightly bigger ID then the Suzuki’s so there should not be a problem with the flow. If someone wants to modify the GSXR fuelrail for "Flow True" fuel flow itīs easy to pull the endplugs and thread the rail ends, drill and thread the plugs and use a glidepuller with a pin that fits the thread. The hole left after the plug is 12mm in diameter and 15mm deep so M14 or 1/4" should be fine. The orignal fuel fitting can be used for a fuelpressure guage or easily blanked of with a plate or a threaded plug. The inside diameter of the Gixxer rail is 9mm in the ends but narrows down to 6mm in the middle.

The new fuelrail in made of a stainless pipe with 14mm ID and 1,6mm wallthicknes, the injector fittings are welded in place and the end fittings is made separate, pressfitted and welded.

The rail bracket is made of four pieces of stainless 1,5mm thick sheetmetal and welded to the rail.

I use the Gixxer skrews and distances to hold the rail in the same way as the original rail, this way the brackets can be made smaller and itīs easier to get the placement right the first time.

Well, I was planning of using standard hydrolic parts as fuel lines but then I came across Russell Performance Products that manufactures aluminium fittings and braided lines. Russell have the ugly ordinary Red and Blue but they also have the fittings in something they call Endura finish that looks like stainless steel and should not be so sensetive of scratches. It looks like iīm going for the Russell fittings but the downside is that I havenīt found any Swedish dealers for Russell parts so I maybe have to get it from JEGīs in the States.According to Edelbrock USA there are European dealers for Russell parts in Germany and in the Netherlands, KTS American in Germany and C&P USA PARTS in the Netherlands.

If I was going for the Red and Blue fittings it would be easy to use the fittings from Earlīs Performance Plumming as I found a Swedish dealer, NBM Hydraulic or Hydroscand.

The plumming of the fixed parts as the pump, filter, regulator and so on is going to be made with fuel rubber hoses and clamps as ther is not enough room to use braided lines and fittings but for a nice look Iīm using braided from the filter to the rail and the return to the FPR.

The fuelpump for the EFI is a MSD 2225, this is an inline-pump that flows 3,0 lit/min at 50psi (3,5bar) without using to much current (5,2A) or if you want a used fuelpump there is the Bosch 254909 that flows a little more but uses more current.

The Gixxer injectors at 200hp needs roughly 1.5 lit/min.

The OBX Racing Sports fuel pressure regulator is an adjustible boost sensing 1:1 regulator with a pressur gauge mounted on it but the guage is going to be relocaded so I can check the pressure when driving. The threads on the OBX are 1/8"x28 BSP for fuel in and out I intend to drill and thread it to something bigger when I have decided on the hose size. It looks like Iīm going for the JIC -06 full flow connectors and hose size -06 (ID ~9mm)

The inline fuel filter is a Mahle KL5 that is a standard fuel filter from a Volvo 240 1975-1980 with B21E engine. The size is 55mm x 130mm and the threads on the filter are  In - M14x1,5, Out - M12x1,5.