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View Full Version : My 2002 Supercharged Hayabusa.


HOS
10-29-2008, 06:58 AM
Superchargers can work and they can work well. I know that turbos are pretty rare, but if you Google Supercharged Busas, mine is about the only bike listed in the world.
But of course there are more out there in the real world.

I have owned 4 previous Busas and this is my 5th and most heavily modified. After seeing a couple of supercharged bikes at Santa Pod ( my local track) in England I decided a few years ago, thats what I want !

Time between saw me receiving serious injuries in a near fatal accident where I got smacked hard by a car that didnt stop and left me for dead in a ditch
under my Hayabusa at the side of a country road, unconscious with less than an hour to live. Luckily I was made of stronger stuff than most and survived.

Finally last year after all the dust had settled on my medical treatment, insurance assessments and medical reports, I was able to start building the bike I wanted :cheers:

The starting point was an 02 model bone stocker Hayabusa in black and blue..... appropriate colours :oh yeah: This bike had only 10k miles on it, 2 owners and nill hard use. A real weekend, old boys bike.

Then I had it.

I had it modified almost straight away to fit the Yoshimura Cyclone "Race use only" 4 into 1 stainless with tri-oval race can. Airbox mods, pair valves removed, Power Commander and dyno time.
This was just the start a long a road of modification that is far from over today....its "ongoing" as they say.
I played around on the road for a few months with it just having been piped and chipped, but wasnt totally happy with the power delivery, it needed more.

So I talked to the only man in the UK I reckon with the talent and expertese to fit me a blower and to do it right !

The prime goal was for RELIABILITY above everything else.
That was my most important criteria for my bike.
This meant we had to plan the build as the engine builder Mark is a top drag racer and his work is all about building drag bikes that are designed to go blindingly fast and get stripped down and rebuilt after every race or two.
That was`nt his brief when it came to my bike and we both went through a really close and interesting learning curve with the bike.

Mark is full of energy and go fast !!!! He is a low 7 second standing 1/4 man on his own blown (road legal) Busa. Yeah... hes fast ! :oh yeah:
He came round slowly to the way of thinking... R E L I A B I L I T Y .
The bike/engine build evolved as we went along.
I spent a fair amount of time in his unit talking with him and deciding on best/better options for the road.
Because it is primarly a road bike but with the ability to race !

I took a while and I was getting anxious to get it out on the road and play with it !
The day it was ready I was nervous. The roads were very damp, wet even and I`m collecting a rapid and mentalist blown Busa ! I`m racked up wtih pain most of the time anyway, so when its wet and slippery as well...... hmmmm....
Mark had test ridden the bike well to make sure it wouldnt let me down or slap me down the road, it was all part of the service he gives.
He wanted me to be totally happy with the bike, something he repeated to me again and again at each stage. For no other reason that he wanted me to be happy knowing a little of how I got there.
Mark was extremely excited and pleased with the bike when we talked the morning of the day I was picking it up. Wheelies in every gear I seem to remember he said ? (I was running stock wheelbase at that time)
He loves this bike and he did oh so NOT want to give it back to me that day. It became his baby.

I now have the best running and rideable bike I have ever ridden in my 38 years of riding bikes. You cannot imagine what this is like on the road and my words arent good enough to express it.
Turbos sound cool, this sounds nasty ! It rips your ears hard.
Smoooooooooth as ice on the throttle. Liquid and fluid seemless POWER. Stunning and deceptively rapid.
Perfect fuelling all the way through the revs range.
Sit the bike at 2000rpm in 6th gear cruising easily in the sunshine.... wind that throttle as hard as you like without changing gear or any hesitancy and its smacked you hard into the seat hump and gone to the horizon without a hitch.
Gear changes become irrelevant on this bike, you can of course drop it down a gear or two and nail it if your in the mind to.
The rush is badass when your hitting 6000rpm in 6th and it takes off with that big turbine whistle and whooosh of the blower, nothing, but nothing can or will stay with you. ~Unless they`ve got boost.
People round here do`nt bother looking when a noisey bike comes past, but the whole street does with this !
The local traffic cops keep overtaking me when I`m cruising thro town, they then turn off and swing back around so they can overtake me again just to look at the bike... I aint joking.


There is no power curve on the graph, its a straight line increase in power from 2000 rpm to the top.
Running at 7 psi boost tops, its hitting max 234 rear wheel horsepower.
For the road thats enough..... well for now... :oh yeah:

MR..X
10-29-2008, 09:24 AM
Good read ,:thumbs up:
Glad you lived to tell this story :cheers:
:rocket bike:
Where are the pics :poke_red_x:

DOOM&GLOOM
10-29-2008, 05:08 PM
Good read ,:thumbs up:
Glad you lived to tell this story :cheers:
:rocket bike:
Where are the pics :poke_red_x:

:pics::pics::pics::pics::pics:

HOS
10-31-2008, 08:32 AM
As I bought it in Jan 2007 a bone stocker.... (except the DB screen)

http://i2.photobucket.com/albums/y8/HUMANHYBRID/Busa05.jpg

HOS
10-31-2008, 08:38 AM
1st stage during spring 07 was to fit the Yoshi, do the airbox mods, fit BMC race air filter, remove pair valves, PowerCommander and dyno time.
I did afew other mods to my personal taste like the Harris Engineering Racing rearsets, helps me position the pegs to suit my damaged pelvis/hips.
Also fitted the Italian wave discs front and rear.

http://i2.photobucket.com/albums/y8/HUMANHYBRID/Leftrear_IMGMedium.jpg

HOS
10-31-2008, 08:47 AM
So by late summer 07 I was bored with it, having had 4 previous Busas modified much the same, so I decided the time was right to get the supercharger done. The summer had been a wash out so nothing much to be lost and I had another ride to use.

In the workshop:
http://i2.photobucket.com/albums/y8/HUMANHYBRID/BusaWork01.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/BusaWorkshop02.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/BusaWorkshop01.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0185.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/BusaWorkshop06.jpg

HOS
10-31-2008, 08:48 AM
Finally blower on and running using a generic fuel map.
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0198.jpg

Oil cooler located infront of headstock...
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0199Large.jpg

HOS
10-31-2008, 09:08 AM
Autumn 07 the Busa came home all work done for that stage.
Couple of other bits added like the Ohlins over frame steering damper and a few stainless bits.

Dyno work was done at BigCC racing by Mark the bike builder and Sean Mills who is BigCC !
Upgarded fule pump was not big enough for th job, fuelling was week at the top end, so after a days dyno time Mark and Sean decide dto sling the upgraded fuel pump and upgraded fule regulator and fit class 1 race spec items. Another day spent on the dyno and it was right !!
Twin fuel maps vai the PC3 USB multi port hub. Handlebar switch.
Setting A : Fuelling for normal road use and economy max 216 rwhp
Setting B : Full on fuelling all through the rev range max 234 rwhp.

http://i2.photobucket.com/albums/y8/HUMANHYBRID/front3quarter.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/frontend.jpg

HOS
10-31-2008, 09:10 AM
Dyno chart:

http://i2.photobucket.com/albums/y8/HUMANHYBRID/BusadynomapAMedium.jpg

HOS
10-31-2008, 09:17 AM
The Spec:

Small capacity Rotrex blower.
Samco dump valve.
Rotrex Inter cooler.
Wide pulley wheels.
Cometic gaskets cyl head and base of barrels.
JMC Turbo pistons and rings.
Custom alloy plenum chamber.
Class 1 race billet fuel pump and regulator.
PC3 USB/ multi use hub and PC ignition module.
H/Duty fuel lines.
Welded clutch centre and stock plates.
New but OE camshafts and valves for reliability.
Stock conrods and main bearings.
Rerouted Yoshi header pipes to miss the blower.
New oil cooler relocated above front wheel and ducted under nose cone.....

DOOM&GLOOM
10-31-2008, 09:34 AM
Nice job HOS, thanks for the pic's we appreciate it !!!

What was the total damege to the pocket book for this to be done?

HOS
10-31-2008, 09:44 AM
Work followed on including:

Painted and polished wheels.
Trimmed the fairing around the Orient Express clutch casing, due to heat and transfer.
Show chromed the pulley wheel cover.
Fitted Pazzo Racing shorty levers.

http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0281.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0223.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/ClutchAfterMedium.jpg

Then a big job ! 6" over swingarm plus all the associated work :head meets wall:

HOS
10-31-2008, 09:47 AM
Nice job HOS, thanks for the pic's we appreciate it !!!

What was the total damege to the pocket book for this to be done?

Total damage to date, bearing in mind apart from the engine build I did the rest myself costing nowt in terms of labour costs.... in the region of £15,000 to £20,000 UK Sterling.

I havent finished the build details yet either ! :oh yeah:

HOS
10-31-2008, 09:53 AM
Billet extensions to swingarm.... quality work !

http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0227.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0230.jpg

Then once polsihed and fitted with new bearings, new dust seals etc... it all starts to go back in ...

http://i2.photobucket.com/albums/y8/HUMANHYBRID/Rearcloseup-1.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/Sprocketcloseup-1.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0240.jpg

HOS
10-31-2008, 09:56 AM
This is the swimgram current version ...
with custom made adjustable torque arm.

http://i2.photobucket.com/albums/y8/HUMANHYBRID/Licenseplate-1.jpg

HOS
10-31-2008, 10:03 AM
So I ended up with a Tsubaki Gold XHD 150 link drag chain cut down to length and Renthal hard anodised rear sprocket.
Titanium caliper bolts, Ti pinch bolts, stainless bleed nipples, polished stainless disc bolts, Earls braided hoses.
Removing the rea pegs was a necessity.... this is not a pillion bike !
So I fitted a Akrapovich exhaust hanger bracket adapted to the Yoshi and show chromed.
Then came the LED rear stop lamp with integral indicators and an "off the peg" rear license plate holder bracket that I broke this year.

HOS
10-31-2008, 10:08 AM
While the swingarm work was underway I invested in probably the only bit of what I would consider to be "bling" from the US :whistling:

A PMR billet alloy top yoke !

Love it !! But hated the install !!! :head meets wall: Did anyone mention Suzuki chocolate metal security screws ? :rant:

Here it is during install ...
http://i2.photobucket.com/albums/y8/HUMANHYBRID/IMG_0270.jpg

HOS
10-31-2008, 10:17 AM
Carbon inner fairing panels followed coupled with new polished stainless steel fairing fasteners all round.
Fitted a show chromed billet alloy Harris racing quick release gas tank cap. Billet engraved clutch and brake fluid reservoir caps.
New horn to replace the rusty old un.

That about ties it up for now on work done.

Its all to my specifications and my design/ ideas. Its my build and I`m very pleased with it.
I had a Dutch dealer express a big interest in buying my bike its so rare, but some things have no price. This is my baby.

Its been a very great deal of hard work to get it this far but worth every second of every hour spent !! :cheers:

HOS
10-31-2008, 10:20 AM
As it is now minus side panel so you can see the detail :

http://i2.photobucket.com/albums/y8/HUMANHYBRID/NakedBusa01Large.jpg

http://i2.photobucket.com/albums/y8/HUMANHYBRID/NakedBusa02Large.jpg

HOS
10-31-2008, 10:25 AM
Had to indulge in a little fun after all the hard work with the enginering and building part !
So heres my seat hump with 3D graphics and my Simpson DiamondBack lid with same 3D graphics.... got to look right !!!

http://i2.photobucket.com/albums/y8/HUMANHYBRID/HYABUSATail2.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/HYABUSAHelmet2.jpg
http://i2.photobucket.com/albums/y8/HUMANHYBRID/HYABUSAcomp2.jpg

HOS
10-31-2008, 10:33 AM
Looks not far from stock, but got the go fast bits...

http://i2.photobucket.com/albums/y8/HUMANHYBRID/BusaatPauls08.jpg

Planning the next stages of modification to start January next year.

MR..X
11-02-2008, 04:57 PM
Looks good HOS :cheers:
AWESOME :smoke:

HOS
11-02-2008, 05:09 PM
Cheers Mr X.

Its encouraging when you post all this amount of detail to know a couple of members are interested. Appreciated mate :cheers:

DOOM&GLOOM
11-02-2008, 05:11 PM
Thanks so much for explaining all the detail that you put in your bike.

Its an absolute masterpiece, know how does it sound?:cheers:

Cheers mate.

MR..X
11-02-2008, 07:45 PM
Thanks so much for explaining all the detail that you put in your bike.

Its an absolute masterpiece, know how does it sound?:cheers:

Cheers mate.

YES a sound file !!
I want to hear that MONSTER :smoke:

greenb5
11-02-2008, 08:49 PM
Thanks for sharing HOS. :cheers:
A very different and impressive build-up.

1WildTurkey
11-02-2008, 10:30 PM
Your bike is nothing short of AMAZING!!! :thumbs up::thumbs up::thumbs up:

HOS
11-03-2008, 03:27 AM
Thanks again guys.

Now thats summat I`ve never done an MP3 file online...hmmmm....
Sorry it `ll have to wait till next year, Busa is offline till then.

After cooking 2 clutches this year because of wrong choices of: A. clutch plates and then B. wrong choice of oil. I then had a pulley wheel break on me in August. Got it all back together recently to find the oil seal on the end of the crank is blowing a fine mist of oil, so its down now till I can get the new spec of seal and end bearing for the crank adaptor.

Busy back at college right now retraining for a new profession in a bit of a pioneering field. The construction industry is dead in the UK so I`m out and moving on :thumbs up: Taking up a lot of my time.
At 49 years of age, does this school thing ever end ? :rofl: