Triumphrat

binglax09 · 05-02-2009, 08:37 PM

Ok so the TT600 that I have been restoring for the past year is finally coming together. I need a little help with routing since I have never seen the bike together nor images of one together.

If you could take a look at the photos in my google album and note anything you see wrong that would help so much!! Also if you have any images of your set-up that would help as well. Here is the link to my album http://picasaweb.google.com/AjaDiGir...eat=directlink

1: How are the breather tubes supposed to be routed? The front one and the side one. It seams like there are to many for the number of nipples on the intake box
2: what is the gray connector in the photo with the motor mount bolt? next to the fuel tube.
3: Is the wiring harness pancake supposed to be between the motor and frame or someplace else?
4: This is a 06 S4 motor with a 03 TT clutch cable mount. Is this mount different since as you can see in the photo the cable is no straight from the mount.
5: how is the throttle cable routed?
6: what hose goes to the fuel pressure regulator?

Thanks for your time!!

P.S. You can also comment on the images themselves if that would work better...

BombFactory · 05-02-2009, 10:22 PM

I'll try to answer some of these if my memory is still kicking:

1. It looks like you have the wrong breather hose on the right side. The right side hose has a tight 'z' in it and attaches to the larger right airbox barb, the IACV hose attaches to the airbox right above the mounting bracket (looks correct). Those are the only large hose that attach to the airbox, but you show a third going off to the left.

The far right smaller barb is where the corrugated tubing for the ECM goes.

There is also thin-walled tube (about 3/8 id) that attaches to the airbox as the drain which is routed down the left side along with the fuel tank drain and overflow drain. That should be all the hoses for the airbox.

2. Gray connector is for California emissions equipment. If you don't have that equipped, it rests on the transmission.

3. Does really matter. If it fits some where, cool.

4. Later model S4's have a longer clutch lifter arm where the cable attaches, as the earlier S4 and TT600 cable lines up straight using a TT600 bracket. You can try to take the bracket off and bend the mounting ears so the bracket goes in a little. If that doesn't work, you'll need to find an 04-06 S4 bracket.

5. My throttle cable goes in front of the right fork tube, goes through a holding ring bracket fastened to the front subframe mounting bolt, and behind the right fork tube, and then loops into the throttle body routed behind the upper radiator hose. They are sometimes tricky to route, as if they are too tight, the engine rpm will increase when the front wheel is turned out each way.

6. No hose to the fuel pressure regulator. Don't ask me why.

What I have said is not to say that this is exactly how the factory routed everything, but it works perfectly for me.

binglax09 · 05-02-2009, 10:51 PM

Wow, great help! Less to it then I thought...

1: I added two more photos, here is a good one of the hose routing http://picasaweb.google.com/lh/photo...eat=directlink

Starting from left to right:
A:second intake nipple to IAC
B: third intake nipple to right engine cover
C: forth intake nipple to front head baffles (whatever they are)
D: last intake nipple to ECM.

does that make any sense? The one from the head to the intake is routed between the 2nd and 3rd throttle body. At least that's how I routed it.

2: I just don't want it to get toasted somehow. I would not want to rebuild the harness.
3: I'm in Maine so no CA bs!
4: It's $10 bucks for a new one on bikebandit but idono which I need since it states weird serial numbers.
5: Thanks!
6: Weird but GREAT! I don't need to buy anymore random parts that can't be found.

Another questions:
7: In the image with the gray connector, what is that screw hole on the block? I already have the ground on the starter bolt so what is this screw hole for?

BombFactory · 05-03-2009, 12:58 AM

1. Your engine does have CA emissions on it if it has the secondary air injection valves on the front of the head. Late model S4 engines are different than early ones in that they use a SAI valve solenoid that I would imagine goes somewhere in that line leading to the SAI valves. This may also mean that the airbox is different, so if you are using a TT600 airbox, it might not have the proper fittings for the late model S4 setup. You can either get all the appropriate parts for the SAI, or you can figure out how to remove it.

I don't agree that the emissions devices are 'bs,' as they don't affect performance whatsoever, but do help the environment (something we will all need to do eventually anyway). All the system does is injects a burst of air into the exhaust to better burn raw fuel that made it through the combustion chambers.

4. You need a bracket for whatever year the engine is.

7. I don't know.

binglax09 · 05-03-2009, 12:05 PM

Well I guess I have to get a S4 ECM w/ out SAI mapped and then block off the SAI valves on the front of the head.

Does that work out correctly? since If I dont use it then a CEL will come on.

This motor is the 05 out of Jeffs D650 swap he did a while back so that gives a point of reference.

Edit: although can I use the TT600 ECM with the S4 cams?

BombFactory · 05-03-2009, 01:46 PM

You don't need a new ECM, you will need to load an S4 map though--before even energizing the system. I can never remember the order, but there have been reported cases of people attempting to use an S4 map in a TT600, or vise versa, and the instrument panel bugs out and must be replaced.

The MIL will not trigger if you have a proper SAI map installed (actually, the TT600 SAI map is often times used on non-SAI TT600 engines for a smoother running condition). You will need to block off the valves somehow.

binglax09 · 05-03-2009, 04:14 PM

Here is what I have in the bike right now.

03 TT600 frame, wiring etc.
w/ 05 S4 engine & ECM

Can I run this without the SAI connected and just start her right up or is there something I need to do so that the system doesnt tweak? like you said.

I guess I just don't know what my plan of action is right now.

1: buy the parts to put the SAI back together and run the 05 S4 ECM
2: block it off and run the ECM anyway
3: I can get a 03 s4 non-SAI ECM shipped to me for next to nothing if need be?

BombFactory · 05-03-2009, 04:21 PM

TT600 and S4 ECMs are the same unit; you do not need to change ECMs to change the maps. You do need either a dealership tool, TuneBoy, or Power Commander to change the ECM map. If the ECM you plan on using has an S4 map loaded (SAI or non-SAI), there shouldn't be an issue.

binglax09 · 05-03-2009, 04:27 PM

I realize that but I would have to pay a dealer, get a tuneboy, or power commander in order to just flash a S4 non-SAI on there. correct? will the MIL come on if there is no SAI hooked up to the system?

BombFactory · 05-05-2009, 10:57 PM

Quote:

Originally Posted by BombFactory

6. No hose to the fuel pressure regulator. Don't ask me why.

This person is horribly wrong!

:

:

I worked on the Speed-TT today and found that there is a hose to the fuel pressure regulator. I was confused with the Daytona 955i which has the barb on the regulator but does not use a hose.

There is a small vacuum hose piece (about 1 inch long) that connects to the fuel pressure reg, then to a 'T' connector. One end of the 'T' goes to the ECM (corrugated tubing), the other goes to the far right barb on the airbox (corrugated tubing).