Parts and Materials:
1. Turbocharger: A small turbocharger designed for use with small engines. Choose one that is compatible with your pocket bike engine's size and displacement.
2. Exhaust Manifold: A custom exhaust manifold that connects the turbocharger to your engine's exhaust outlet.
3. Intake Manifold: A custom intake manifold that connects the turbocharger to your carburetor or throttle body.
4. Intercooler: A small air-to-air intercooler to help cool the compressed air from the turbocharger before it enters the engine.
5. Oil Feed and Drain Lines: Oil feed and drain lines to supply oil to the turbocharger and return it to the engine.
6. Oil filter: An inline oil filter to protect the turbocharger from any debris.
7. Boost Controller: A boost controller helps regulate how much boost pressure the turbocharger produces.
8. Fuel Pressure Regulator: A fuel pressure regulator to increase the fuel pressure to meet the increased demand for fuel when the turbocharger is engaged.
Steps to Make a Pocket Bike Turbo:
1. Engine Preparation:
- Before attempting any modifications, ensure your pocket bike's engine is in good condition. Any underlying problems should be addressed first.
- Verify that the engine has sufficient compression and is running reliably.
2. Mount Turbocharger:
- Attach the custom exhaust manifold to the engine's exhaust outlet. Ensure a secure and airtight fit.
- Mount the turbocharger on the exhaust manifold using the appropriate bolts and gaskets.
3. Connect Intake:
- Attach the intake manifold to the carburetor or throttle body and ensure a proper seal.
- Connect the intercooler between the turbocharger and the intake manifold.
4. Oil Supply:
- Install the oil feed line from the engine's oil pump outlet to the turbocharger's oil inlet port.
- Install the oil drain line from the turbocharger's oil drain port to a suitable location on the engine.
- Make sure the oil lines are securely connected and free from sharp bends or kinks.
5. Fuel Modification:
- Install a fuel pressure regulator in-line with the fuel line to increase fuel pressure. Ensure it is adjustable based on the boost pressure you intend to run.
6. Electrical Connections:
- Connect the turbocharger's wastegate actuator (if equipped) to a vacuum source on the engine.
- Connect the boost pressure sensor (if not included in the turbocharger kit) to a suitable location after the intercooler. This sensor will provide feedback to the boost controller.
- Connect the boost controller according to the manufacturer's instructions. It should receive signals from the boost pressure sensor and control the wastegate actuator to regulate boost pressure.
7. Tuning and Testing:
- Start the pocket bike and let it run for a few minutes to allow the turbocharger to prime and circulate oil.
- Slowly increase the boost pressure using the boost controller while closely monitoring the engine's performance.
- Make necessary adjustments to the carburetor or fuel injection system to ensureproper air-fuel mixture and avoid any lean conditions.
- Break in the turbocharger properly by gradually increasing boost pressure and varying engine RPM.
8. Safety Precautions:
- Always use safety glasses and gloves when working on your pocket bike.
- Be aware of the increased risks associated with a modified engine, especially potential hazards like engine overheating, excessive boost pressure, and fuel starvation.
- Make sure the turbocharger and exhaust are securely mounted to prevent any parts from coming loose.
Note:
- Modifying a pocket bike engine with a turbocharger can significantly alter its performance and void any existing warranties.
- Professional advice or the guidance of an experienced mechanic is highly recommended to safely and effectively install and tune a turbo on a pocket bike.
Again, attempting modifications like this can come with risks, so it's essential to carefully research and consult experts before attempting any modifications to avoid compromising safety or causing damage to your pocket bike.
