The Super Mario Hayabusa — Extreme Street Motorcycle

The 1,547 cc Super Mario Hayabusa engine

The Super Mario Hayabusa was based on Sean Mills' Project Pisstake, the extreme 1,547 cc turbocharged Hayabusa engine project that provided the foundation for the build.

When custom motorcycle builder Mario Kleff became involved with the project, his original intention was to install the engine in a custom chopper. During the engine development, however, he came to the conclusion that the engine would be better suited to a much smaller machine. The idea subsequently evolved around a mini scooter, creating the striking contrast between the light-weight chassis and the powerful Hayabusa powerplant.

From its first dyno runs through its subsequent development by Sean Mills, it remaines the Super Mario Hayabusa.

The engine was based on the first-generation GSX1300R Hayabusa architecture and developed to 1,547 cc, using a long-stroke billet crankshaft, enlarged bore, forged low-compression pistons, high-strength connecting rods, a billet clutch, and sophisticated engine management.

Big CC increased the standard 63 mm stroke by approximately 8.5 mm to around 71.5 mm and increased the bore to 83 mm, producing approximately 1,547 cc.

The engine was built for extreme turbocharged cylinder pressures rather than simply producing a large displacement. Carrillo connecting rods made to Wössner specification, forged Wössner pistons, a billet MTC clutch, large racing injectors and MoTeC engine management formed the core of the build.

A large turbocharger supplied the compressed air required for the increasingly ambitious dyno program.

The Super Mario Hayabusa—632 hp to 776 hp

The original dyno development of the Super Mario Hayabusa produced a series of increasing figures:

632 hp → 669 hp → 687 hp → 752 hp → 776 hp

The development ultimately reached approximately 776 horsepower at the rear wheel.

That distinction is important: these were rear-wheel horsepower figures, not crankshaft horsepower.

But 776 hp was not the end of the Super Mario Hayabusa story.

After final inspection, Mario Kleff is getting the engine shipped for his custom bike project "Super Mario".

The Super Mario Hayabusa—776 hp to 936 bhp

In 2016, Mario Kleff sold the engine back to Sean Mills.

Sean then continued developing the same 1,547 cc Super Mario Hayabusa engine at Big CC.

The engine was pushed beyond the original 776 hp figure, first moving through the 800-horsepower range and subsequently into the 900+ horsepower range as boost and the turbo system were further developed.

At approximately 46 psi of boost, the engine ultimately produced approximately 936 bhp.

The development therefore progressed:

632 hp → 669 hp → 687 hp → 752 hp → 776 hp → 800+ hp → 900+ hp

Approximately 936 bhp at 46 psi

The important point is that 776 hp and 936 bhp are different stages in the development of the Super Mario Hayabusa engine.

The name did not change. The engine did not suddenly become a different project. The Super Mario Hayabusa engine simply continued to be developed after Mario sold it back to Sean.

The Super Mario Hayabusa and Phil Wood

The later development of the Super Mario Hayabusa engine eventually led to the motorcycle being tested and ridden by British drag racer Phil Wood.

Mario Kleff was invited to ride the motorcycle himself but did not try.

With the engine capable of producing close to 1,000 horsepower, the Super Mario Hayabusa required extensive chassis preparation. A special 8-inch rear wheel was constructed to accommodate a 240-section tire, the rear swingarm was strengthened, and the frame was modified to provide a suitable chain line.

Variable boost was also important. Using the engine's full potential on the road would make traction extremely difficult, so the boost could be reduced according to the requirements of the run.

Wood subsequently tested the Super Mario Hayabusa at very high speed. At Elvington in Yorkshire, he recorded 271.821 mph (437.453 km/h) on a flying-quarter-mile run, with boost reduced from the engine's maximum potential to help control traction.

The complete Super Mario Hayabusa progression

The history can therefore be followed as one continuous development:

• Project Pisstake—Sean Mills' 1,547 cc extreme turbocharged Hayabusa engine project and the engineering basis for the Super Mario Hayabusa.
• Super Mario Hayabusa—Mario Kleff's motorcycle project based on the Project Pisstake engine concept.
• 1,547 cc—heavily stroked and turbocharged Hayabusa engine Gen 1
• 632 hp → 669 hp → 687 hp → 752 hp → 776 hp — original Super Mario Hayabusa dyno development.
• 800+ hp—continued development by Mills at Big CC.
• 900+ hp—further development of the same engine.
• Approximately 936 bhp at 46 psi—a later high-boost development figure.
• The Super Mario Hayabusa was throttled to around 660 hp for test runs in street-legal bike to determine its top speed.
• Phil Wood—subsequently tested and rode the Super Mario Hayabusa.
• 271.821 mph (437.453 km/h)—Elvington flying-quarter-mile run.

The Super Mario Hayabusa, therefore, has a continuous technical lineage from Project Pisstake through 776 hp and ultimately to approximately 936 bhp.

Other Images of the Super Mario Hayabusa Development

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