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Beans kp60 3 door running a 5k on bike carbs


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well ive not really post about this but i bought a kp at the start of summer last year. i searched for over a year before i found it and i was very lucky to stumble upon it as it wasnt actually up for sale.

heres a bit about it and what ive done with it up to now. its copied and pasted from another thread from a bit ago. so it wont quite make sense.

i only had the car a week and the mot ran out so then its sat for a week while i sorted a few problems out but i will get to them. re test is today at 2pm. but i need to catch some sleep first.

first thing i did when i got the car was get it booked in on the dyno as i knew the carbs hadnt been setup properly. good job i did too.

heres a couple of pics on JDM's dyno

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and the result

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from how the car goes on the road i was expecting a bit more power but i guess these are really lightweight cars.

the run showed how the fueling needs quite a bit of tweaking. its really rich low down and really lean high up! you can see after 4.5k rpm it leans right out making the torque drop off. so JDM said i need to order a stage 3 dyno jet kit for my carbs. I know pretty much nothing about carbs so he had a bit of explaining to do to me.

so when i get the kit i will be booking it straight back in for tuning. but i cant find a stage 3 kit listed for cbr900 carbs and it doesnt help that i dont know what year carbs they are. i just havent had chance to ring dynojet or find out what i need to buy exactly for them.

anyway then a few days after that it was mot time.

it needed 2 rear wheel bearings, i took the shafts out and took them to a guy at work with the new bearings and he fitted them for me. i changed the rear diff oil to some quality motul lsd oil too and fitted new gaskets onto the end of the half shafts.

i also had one tyre wider than the other but they were both not very good tyres so i bought 2 new yoko a539's and put them on the back and the slightly worn ones on the front.

it also had a problem with the front dampers one was really stiff and one was really soft so i got a set of gaz inserts and fitted those.

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old bilsteins next to the new gaz inserts. there pretty much the exact same length

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so its all ready for its mot hopefully.

next post

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im gutted i ordered the 50 profile tires instead of the 60 ones. i will have to get them next time.

i rang dyno jet up today too about sorting my carbs out and they were absolutely useless no help at all. they just said i would have to go to one of there dedicated dynojet tuning centers. which i wont be doing.

next post

rear diff gasket was changed and the drain plug and both washers which has solved the leaking diff, polly bushes are fitted in the link arms now. and...

ive also had it with my tuner for almost a week now. the most its made so far is 118bhp and it has a nice long power band which doesnt drop off. the fuel pump was flooding the carbs so i had to order a low pressure fuel reg so that arrived today and we got that fitted and its had some more adjustments and its solved the flooding problem. its now been taken to almost 6k rpm running good. its a little rich low down still as the needles cant be dropped any more to lean it out, and a little lean top end with 160 jets. so i need to get hold of a 1.65mm drill and then we can try 165 jets and see how it goes.

its ticking over much better now and reving up nicer and it just sounds sweeter so im looking forward to driving it when its done. hopefully it will be sorted for sunday as im entering an auto solo. it looks like ive got free entry too which is nice.

heres some vids

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next post

had it back on the dyno today with the jets drill out .5mm more and timing advanced 2 degrees more.

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job done!

thats about it really. the car is now parked up for winter . im just waiting on a new garage door to be fitted and then it will be going into hibernation. i plan to take the engine and box out fix the oil leaks (already have a toyota sump gasket and heaps of gasket kits) then give the bay and front end a good rub down and get it sprayed. might do it my self and see how it goes.

i want to tidy a few other bits up like the bumpers ect too. the car needs no welding as its very clean just a bit of a tidy up really.

this arrived the other day too. brand new still in toyota packaging!

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well we've had a few nice bits of better weather and i really wish i could have had the kp out for a blast about so i thought i better make a start.

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i got the front end pretty much much stripped, removed a few wires ready to take the 5k out. unbolted the exhaust and loosened of the gearbox mount ready to wip it out. shouldnt take much now to get it out. hopefully if the weather ok i will get some more done next week. i want to get cracking with it now.

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ive gathered various parts incase i wanted to go 4age or 20v which i may do in the future. problem is all the ae86 parts and 20v parts are in ireland, hardly anything over here so postage on stuff will cost a bomb.

so I plan to keep the 5k. i was going to get a bigger cam reground for it from kent but i dont know if i can be bothered now. ive never built an engine before and i think it would be alot of work for little gains when it already runs great as it is. ive thought about converting it to fuel injection using a dta s80 standalone i have. i would get a set of throttle bodies from a newer cbr 900 then they should fit the inlet, then fit a trigger wheel on the crank pulley for a crank sensor and then run a coilpack setup, swirl pot, fuel pump ect. it would run alot better efi and maybe squeeze a little more out of it.

for now i will be replacing some gaskets on the engine, checking the condition of the clutch, sealing up the gearbox and rear diff (everything leaks oil on it)

you cant really tell in the pic but at some point the slam panel has been painted and its just been done with a brush and doesnt look too good so i want that sorted and the dent knocked out the inner wing which was to make room for an old carb setup. then get the bay sprayed or maybe the whole car. i dont know a bodyshop round here i can trust to do a top job though, im really picky with bodyshops. theres loads of them about but one that does a good job is hard to find.

heres a couple of pics

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Heres the engine spec

1500 5k engine from liteace

lightened and balanced bottom end

solid lifters

kent cam - not sure which one but its not a wild one

kent valve springs

ported and polished head

custom borg brothers inlet

cbr900 carbs running dyno jet kit adjustable height needles, different springs and jets drilled out (cant remember what size they are now)

low pressure fuel reg

some pump in the boot.

electronic ignition

timing tweaked a little when it was on the dyno.

standard size bores

some 4-2-1 exhaust mani not sure what it is but it has flat spots in some places (maybe to clear an old carb setup again)

custom tig welded stainless exhaust system (someone made a very nice job of this)

Well not much has been going on with the kp as ive been busy moving house and i did a b18 conversion on my civic i use for work. At the end of August i moved house. finally got a garage of my own! so today in the lashing rain a guy from work helped my move my kp from the little garage it was stored in to my house. :D

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and in the garage reunited at last with his younger brother!

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the reason it took a few months before i brought the kp up was ive been doing alot of work in the garage. it was originally 2 singles so i knocked it though then pulled the ceiling down put insulation up then plaster boarded it and my dad skimmed it. there was no power to it either so i got a guy i know to wire it all up for me, loads of sockets and plenty of strip light. then i cut a doorway though from the garage into the workshop where the picture was taken from.

Hopefully now i can get some progress made on the car now. its sat in a garage for about a year. doesn't seem to have took much harm, theres a few bits that have been touched up in the past which have bubbled up a bit but still solid enough.

Edited by Bean
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Amazing work, i really like these cars, in fact turns out i have got a bit of a soft touch for the old classic machines :) I am just wondering where i go next after my sleeper starlet hmm, cant wait to see it at the shows.

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i love the kp, there just so rare though! and getting parts especially panels for them is so hard, good straight doors, wings, bonnects are like hens teeth.

Its so much fun to drive, alot more so than an ep. The sound of it is great with the carbs. even with just 120 odd bhp its not slow either.

I got the front end stripped off it today ready to start cleaning it up over winter. not sure how far im going to go, either tidy it up a bit and get it out on the road next year when the weather gets better or completely strip and rebuild the whole car, respray the lot. ive got the room to do it now. see how it goes.

oh yeah ive got this for it too

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how cool is that a clear dizzy cap and rotor arm so you can see it sparking! it took me ages to find this! eventually a guy had some NOS in the Philippines, genuine jdm part.

Edited by Bean
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1st starlet i was ever in was a bright yellow KP,same shape.my dad owned it and at 2-3yrs old,i steered it as he done the pedals.1 of my greatest memories of my dad. Car was mint too.

Your1is mint too bean, look after her mate.

4age or an FTE conversion would b amazin!

Never seen 1 with an FTE before,would go like fuck! :-)

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thanks guys, if it was an easy conversion i would put my 5e in it but ive only seen one example of that conversion and it was so much work, not something i would want to take on. no rwd box fits the 4e/5e closest thing is an old supra box i think then you need a custom adapter or belhousing made up and thats just the start of it.

the only way i will find out what cam it has is when i take it out. the cam im thinking of going for is this one, the engine already has the mods to take it, ie the solid lifters, bike carbs, uprated valve springs, p+p head.

cam

i dont know if you guys saw but in this months retro car there is a kp running a cossy yb engine, 380bhp!! it looks mint too.

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Edited by Bean
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Ahh cool, I bought it from a guy in Manchester so mascrat isn't far away. He had Irish family so he went over now and again. I doubt it sat in a field for long mind. If you could get the pics up that would be great!

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nice one be cool if you could get them put up.

i got the front end stripped down on friday

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not quite sure what to do now. i should have a stock cam coming next week though so i can get that sent to kent to be reground.

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  • 2 weeks later...

i whipped the front wings off this yesterday to check what its like underneath. i was very happy with what i found!

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there was loads of crap and dirt in the bottoms of the wings so good job i got that out, and on the passenger side inside the wing i found this!

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a 10mm spanner and a pen??? who knows how long they've been in there!

the cars up on blocks now so i can get a good look under neath. im hoping my uncle comes to see the car soon and see if he will spray it for me. Hes restored a few old rs2000 escorts and hes a perfectionist so hes done a great job of them.

Edited by Bean
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