spyd3rm4n
Well-Known Member
I don't know why but when I spotted a blue 2004 FZ1 with 3000 miles for a great price, I had to buy it. It's been sitting for a long time and wasn't running well, though it did start and idle with the choke on. Previous owner started digging into it to get it running, replacing spark plugs, oil change and filter, and a new amazon/ebay fuel pump (???) but I guess he gave up when he realized the carbs had to be removed and cleaned. The engine starts up on the choke but as soon as you give it throttle or turn the choke off, it dies out.
I got the tank and carbs off and cleaned up that mess. The fuel was horrible, probably still from 2004 or 2005, and was the worst smell I have ever experienced. The tank was surprisingly in good shape aside from a few minor rust spots inside, so I soaked with the Blaster Metal Rescue and put a 3' piece of chain inside to shake around and loosen up.
I got the carbs out and cleaned, using the All Balls rebuild kit. I didn't use any of the included jets, just the o-rings, float bowl gaskets, needle valves, needle holders, and a few miscellaneous screws from the kit. I used the RavenRider jetting, sourcing euro needles from RavenRider himself, and got 127.5 main jets from Sudco. I *did* port the boots; this is one thing I didn't do on my Silver bike. And of course the airbox modification. I cleaned the jets with a piece of wire and thought all was good, and bolted everything back together. I was all excited to fire it up, but it ran exactly like it did before, only idling on choke and engine stalling whenever I tried to give any throttle. I couldn't figure out what was going on, I thought maybe spark plugs but I pulled the plugs and they're brand new NGK CR9E.
So I did some thinking, this behaviour sounds exactly like clogged pilot jets but I thought I cleaned those. Looking at the carb schematic and studying it, I realized I missed the PILOT JETS! I can get the carbs off these bikes in under 30 minutes, but this time was even faster. So off again, and sure enough three of the four pilot jets were completely blocked. I cleaned them up, and then when reassembling the bowl gaskets were stretched and swollen from being exposed to fuel so I had to wait a few hours but finally got them back on and she starts right up and idles perfectly!
I don't know what to do about this fuel pump, it look cheap and sounds weird. I suspect the previous owner incorrectly assumed the idle problems were caused by a faulty fuel pump. (My Silver Gen I has around 60K miles on the orignal 23 year old fuel pump!!!)
Now for a coolant flush, oil change, brake fluid flush, fender removal, new tires, and cleanup of a few crusty fasteners. Is there anything else that needs my attention on a bike that's been stored for almost 20 years?
I got the tank and carbs off and cleaned up that mess. The fuel was horrible, probably still from 2004 or 2005, and was the worst smell I have ever experienced. The tank was surprisingly in good shape aside from a few minor rust spots inside, so I soaked with the Blaster Metal Rescue and put a 3' piece of chain inside to shake around and loosen up.
I got the carbs out and cleaned, using the All Balls rebuild kit. I didn't use any of the included jets, just the o-rings, float bowl gaskets, needle valves, needle holders, and a few miscellaneous screws from the kit. I used the RavenRider jetting, sourcing euro needles from RavenRider himself, and got 127.5 main jets from Sudco. I *did* port the boots; this is one thing I didn't do on my Silver bike. And of course the airbox modification. I cleaned the jets with a piece of wire and thought all was good, and bolted everything back together. I was all excited to fire it up, but it ran exactly like it did before, only idling on choke and engine stalling whenever I tried to give any throttle. I couldn't figure out what was going on, I thought maybe spark plugs but I pulled the plugs and they're brand new NGK CR9E.
So I did some thinking, this behaviour sounds exactly like clogged pilot jets but I thought I cleaned those. Looking at the carb schematic and studying it, I realized I missed the PILOT JETS! I can get the carbs off these bikes in under 30 minutes, but this time was even faster. So off again, and sure enough three of the four pilot jets were completely blocked. I cleaned them up, and then when reassembling the bowl gaskets were stretched and swollen from being exposed to fuel so I had to wait a few hours but finally got them back on and she starts right up and idles perfectly!
I don't know what to do about this fuel pump, it look cheap and sounds weird. I suspect the previous owner incorrectly assumed the idle problems were caused by a faulty fuel pump. (My Silver Gen I has around 60K miles on the orignal 23 year old fuel pump!!!)
Now for a coolant flush, oil change, brake fluid flush, fender removal, new tires, and cleanup of a few crusty fasteners. Is there anything else that needs my attention on a bike that's been stored for almost 20 years?
