Water Injection Honda Innova 125cc 2004 Carburator

Title: Enhance Your 2004 Honda Innova 125cc Carburetor with Water Injection

Are you seeking to enhance the performance and fuel efficiency of your 2004 Honda Innova 125cc Carburetor? Water injection could be the solution you've been searching for. In this comprehensive guide, we will take you through the steps of installing a water injection system specifically designed for your Honda Innova 125cc Carburetor.

To further emphasize the cost-effectiveness and simplicity of the system I'm about to describe, it's important to note that all the components needed for this modification can be acquired for under 10 euros each, and there's no requirement for a pump or any additional electronic components. This makes the solution not only effective but also budget-friendly.

Before we delve into the installation process, it's essential to note one significant modification made to the engine. The piston size has been increased to 54.5 millimeters, deviating from the default 52.5 millimeters. This change is the sole alteration from the stock configuration, with the aim of optimizing the engine's performance.

Installing the water injection system offers a range of advantages, including:

1. Steam Generation: Introducing water from the intake manifold into the system, driven by the high temperatures at the intake valves (exceeding 100 degrees Celsius), causes the water to transform into steam.

2. Enhanced Compression: During the compression stroke of the 4-stroke engine, steam occupies a significant portion of the combustion chamber, significantly increasing the compression ratio, a crucial factor for boosting power in an internal combustion engine.

3. Heat Absorption: During the intake stroke of the 4-stroke engine, water vapor absorbs heat from the engine, which is then converted into steam. This process contributes to engine cooling.

4. Improved Combustion Efficiency: During the exhaust stroke of a 4-stroke engine, steam exits at higher velocity, creating a scavenging effect that assists in expelling exhaust gases and heat. Consequently, the combustion chamber remains cleaner, reducing carbon deposits over time.

5. Friction Reduction: The steam generated during the compression stroke creates a thin film on the cylinder walls and piston surface, reducing friction and mitigating phenomena like piston slap, which was initially observed in the used engine.

6. Knocking Reduction: The water injection system also mitigates knocking, thanks extracting heat from the cylinder charge and, on this basis, reduce final compression temperature.

7. Fuel Efficiency: The combination of increased compression, reduced friction, and enhanced combustion efficiency leads to a substantial reduction in fuel consumption. In this case, it resulted in a remarkable 20% improvement in fuel efficiency.

Installation Steps:

1. Piston Size Modification: Ensure your Honda Innova 125cc Carburetor has a piston size of 54.5 millimeters, as this modification is key to enhancing performance and fuel efficiency.

2. EGR Valve Removal: To start, you'll need to completely remove the EGR valve from its original location. The EGR valve removal is essential to make way for the water injection system. Don't worry; this procedure won't adversely affect your engine.

3. Sealing the Exhaust Port: After removing the EGR valve, you'll find the exhaust port located at the engine's head. This port must be sealed precisely to maintain a closed system with the new water injection setup.

4. IV Flow Regulator Holster: The space where the EGR valve used to be is now available for the IV Flow Regulator Holster. You can download the 3D printable design for this holster for free, making it a cost-effective addition to your setup.

With the necessary preparations completed, proceed with the water injection system installation, successfully tested on a 2004 Honda Innova 125cc Carburetor over 6,000 km without issues. Achieving a notable 20% improvement in fuel efficiency, the system lowered consumption to 2.3 liters per 100 km from the previous 2.8 to 3.1 liters per 100 km.

The secondhand 2004 Honda Innova 125cc Carburetor, purchased with 92,000 km, faced reduced power and torque, not solely due to mileage but also inherent characteristics of these machines. The water injection system effectively addressed these issues.

Thorough testing over 6,000 km revealed no reported issues. Notably, rough engine sounds in how-to videos were primarily attributed to piston slap, a common occurrence in used engines. Although the water injection system didn't entirely eliminate the sound, it significantly reduced it. Post-installation, the engine demonstrated enhanced operation, confirmed through subsequent tests, including volumetric measurements¨

Test:

Precise measurements during controlled trials covered approximately 2 kilometers at 25 km/h, consistently recording a fuel consumption rate of 1.9 liters per 100 km. In urban driving conditions, consumption never exceeded 2.3 liters per 100 km, showcasing the system's reliability.

Volumetric measurements involved external containers for precise fuel quantities and water, directly linked to the carburetor and water injection system, respectively. Testing procedures were carefully repeated.

Spark:

Additionally, it is worth noting that the spark plug was changed precisely at the initiation of the water injection system and has since covered 6000 km. I have photographs depicting its current condition. The color of the spark plug's electrode clearly provides compelling evidence of impeccable combustion without deposits.

1. Spark Pic
2. Spark Pic
3. Spark Pic

These assessments, coupled with the positive impact on fuel efficiency and engine performance, position the water injection system as a promising upgrade for the 2004 Honda Innova 125cc Carburetor. The author adheres to strict testing standards and explores potential enhancements for future iterations.

Acknowledging the experimental nature, the author may explore further upgrades. Special thanks to saftari's article "Water Injection Stage 1" for inspiring this innovative project.(ref.1)

Following this guide and the mentioned modification can unlock your 2004 Honda Innova 125cc Carburetor's full potential, enhancing both fuel efficiency and overall performance. Enjoy your upgraded riding experience!

References:

1. At the outset of this project, I drew inspiration from the work of "Water Injection Stage 1" by saftari, who introduced the idea of utilizing a NEEDLE in this context. The innovative approach of saftari, significantly contributed to the development of this article. I extend my gratitude for their insightful work.
2. When is EGR valve not EGR valve?: when-is-egr-valve-not-egr-valve.html This article is a very important reference for understanding the operation of the EGR valve. It clarifies many of the common misconceptions and myths that people have about this valve. It is a valuable resource for anyone who wants to understand how the EGR valve works.

• Needles G21: Total 4 pieces
• One is Injection Needle Part: a.1
• From other 3 remove the iron needle with a plier and keep only the plastic hub (look Step 2 x2 Part: a.4 and Step 6 Part: f.2)
• Steril spike: 1 piece Part: d.1
• IV flow regulator: 1 piece Part: b.1
• IV bag: 1 piece Part:
• Luer connectors: 2 pieces Part: b.3 + Part: d.2 (had 1 for each IV set)
• Silicone tubing:
• 5mm x 6mm x 25mm: 1 piece Part: f.2
• 5mm x 6mm x 26mm: 1 piece Part: a.2
• 8mm x 4mm x 26mm: 1 piece Part: a.5
• 8mm x 4mm x 24mm: 1 piece Part: b.2
• 8mm x 4mm x 17mm: 1 piece Part: d.3
• 10mm x 6mm x 69mm: 1 piece Part: a.3
• 10mm x 6mm x 310mm: 1 piece Part: c.1

Step 1 A.1: Insert the(part a.1) needle into the (part a.2) 5mm x 6mm x 26mm silicone tubing, as shown in the video.

*The needle and tube in the video is appear at a 120-degree angle. Its easy and better: you may need to adjust this angle after installing the system on intake manifold bike.

Hub Installation

Step 2 A.2: Use a pair of pliers to pull out the metal needle from the plastic hub (x2 plastic HUBS (part: a.4).

Step 2 A.3: Insert one hub into the (part a.3) 10mm x 6 mm x 69 tube from one side.

Step 2 A.4: Insert the other hub (Part: a.4) into the (part a.3) 10mm x 6 mm x 69 tube from the other side.

Make sure that the small holes on the hubs (Parts: a.4) are facing each other.

As shown in the video & Insert the tube with Injection Needle that fabricated in Step 1 into the other side of Palindrome Force Neutralizer, as shown at the end of the video.

Explanation

The hubs (Parts: a.4) are two small, conical pieces of plastic. They have a small hole in the center, where the needle was previously located. These will create a diaphragm inside tube (part a.3). This diaphragm helps to neutralize the reciprocating force of the piston. It is necessary to reduce this force so next the (part b.1) (IV Flow Regulator) can then manage, more effectively.

Step 3 B.1: The (part b.1) IV Flow Regulator has two silicone tubes. You need to cut one of the tubes, the one that goes towards the sterile spike. Cut the tube to a length of 38mm so that you can insert the Luer Connector (part b.3).

Step 3 B.2: Screw the (part b.2) tube into the (part b.3) Luer Connector.

Step 4 C.1 Connect the (part b.2) (from previous step) to one end of the (part c.1) (show on picture here)

Step 5 D.1: Cut the tubing from the (part d.1) Sterile Spike and leave a 38mm section, as shown in the picture.

Step 5 D.2: Connect the Luer connector (part d.2)to the cut tubing from (part d.1) Sterile Spike.

Step 5 D.3: Screw the tubing (part d.3) onto the Luer connector (part d.2)

Step 5 D.4: Connect the tubing (part d.3) to the Large-Bore Tube (part c.1)

Step 6 E.1: Attach the sterile spike (part D.1) to the IV bag (part E.1).

*The IV BAG is installed with cable zip ties but dont had problem..

Optional:

Increase engine power and torque by replacing the default Air-Fuel Mixture Screw with a tube and a hub.

Instructions:

Step 7 F.1:Use a wrench to remove the default Air-Fuel Mixture Screw from the carburetor.

Step 7 F.2:Remove the needle from the needle hub (part f.1).

Step 7 F.3:Enlarge the hole in the (part f.1)hub to 1.5mm.

Step 7 F.4:Insert the hub (part f.1) through the hole onto (part f.2)tube.

Step 7 F.5:Screw the tube (part f.2 with inside (part f.1) onto the carburetor.

Note:

Enlarging the hole to 1.5mm will increase power and torque.

*when the engine is completely cold, it is difficult to keep idle revs. Τhis only happens for two minutes, then it's normal.

If you are willing to accept this disadvantage, then increasing the air-fuel ratio. However, if you don't want to then you should avoid this change. and set the default Air-Fuel Mixture Screw 5.5 turns open!

The water injection system flow rate adjustment process is a bit complex, but I believe that the instructions-photos or videos that will follow soon will help.

Once we have connected all the components of the system correctly and there are no problems with the connections, then we can install the entire network of hoses back on our bike.

Remember that the palindromic force neutralizer must always be mounted horizontally for it to function as correctly as possible!

And we choose to have no kinks in the small hoses of the flow regulator and the sterile spike, especially, but also in the rest.

After connecting it to the water tank IV BAG and the other edge with the injection needle to the intake manifold, then we need to

Adjust the IV flow regulator to a high flow setting of about 200ml/h or even to OPEN.

Then we need to start the engine and let the hose system fill with water towards the intake manifold!

Remember that in this process you should also have to step on the gas a little more in some way or to raise the idle so that the engine does not turn off!

Once we see the first drops of water have reached the palindromic force neutralizer we will see that they are oscillating in that chamber then quickly we must lower the setting on the IV flow regulator to 40ml/h

and look back at the transparent chamber of the sterile spike.

There we will see that the water flows in the form of drops that come from the IV bag

We need to time the drops to check the water flow in our system (because the values ​​listed on the IV flow regulator are not accurate)

So we calculate how much time it takes from the moment a drop is formed inside the sterile spike to drop into the chamber. This is the flow inside our system.

Empirically and with a more complex process, I have calculated that the flow should correspond to

One drop every 4-5 seconds up to 8 never less than 4 seconds.

If the flow time of one drop takes more time than 8 seconds then we need to increase the flow a little from the IV flow regulator setting, if we see that the flow time of one drop is less than 4 seconds then we need to decrease the flow from the IV flow regulator.

Due to the shape and hoses, the sterile spike is mounted horizontally so when we turn off the engine this chamber will be filled with water, which with gravity returns to the IV BAG by itself,

But the next time we start the engine it will not be possible to see the drops and time them.

Of course this is not a problem because you only need one time adjustment.