Date: 18-09-19  Time: 15:11 PM

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Messages - 7uckyDog

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1
For Sale & Wanted / Wanted: Donor Bike FZS600 2000-2003
« on: 16 January 2019, 03:16:55 PM »
Looking for a non running FZS 600 2000-2003, ideally HPI clear as I need to re-frame my bike and swap out the radiator plus other bits. Happy to look at bikes in any state.

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For Sale & Wanted / WANTED: Donor Bike FZS600 2000-2003
« on: 15 January 2019, 09:09:47 PM »
Looking for a non running FZS 600 2000-2003, ideally HPI clear as I need to re-frame my bike and swap out the radiator plus other bits. Happy to look at bikes in any state.

Thanks!

3
General / Re: Frame Swap, What's the Legal Way?
« on: 15 January 2019, 09:02:24 PM »
Getting my bike back this Thursday, so happy to know there’s a way to putting it back on the road, thanks for clearing out my paranoia!

Happy to look at donor bikes as I need a radiator and a fuel tank as well!

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General / Re: Frame Swap, What's the Legal Way?
« on: 13 January 2019, 09:21:59 PM »



The company that assessed the damages on the bike mainly put it in category B because it had category C already on it from a previous crash. I think they were trying to scare me by saying I couldn't use any parts of the bike, they also added that could scrap it for free (so generous of them) or I would have to pay £50 if I do it myself later on.


The bike has loads of good parts, like brand new tires, chain, levers, and other bits and they probably felt like they were gonna make easy money out of my bike. They also valued it £500 under market value which I obviously disputed. I know it's in my right to get the bike back so I'm definitely re-framing it!


My only worry is that after all that work some MOT nerd with too much attention to detail will notice that the VIN and Engine Number don't match and I will have a bloody headache.


What's ya think? Do I have to pay a scrappy to pretend to sell the engine back to me after I give him my old frame?

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General / Re: Frame Swap, What's the Legal Way?
« on: 12 January 2019, 12:57:31 PM »
The engine number is recorded in my V5, maybe I can "sell" the bike at a scrapyard and "buy" the engine off them. The question is if they're allowed to sell big parts like that with serial numbers.

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General / Frame Swap, What's the Legal Way?
« on: 11 January 2019, 07:52:12 PM »
Hello fellow Fazer owners,


I had a very 'nice' Christmas present by an idiot driver who knocked me off my bike so I ended up in the back of a stationary van. Long story short the bike was written off as category B because of damage on the frame.


I've put way too much work into transforming the bike so I'm not ready to part with it and there are loads of good bits on the bike which I can't legally sell. But I'm wondering if I can get the bike on the road again by swapping out the frame if I find a good one with plates and a logbook.


My biggest concern is, can I use the engine? What's the legal way to do this? Does the frame have to be HPI clear or can it be up to Category C? How complicated is the registration procedure? Would be great to hear from anyone that has gone through a similar ordeal!


Thanks in advance!




2002 FZS600

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For Sale & Wanted / SOLD: Givi Monorack arms & plate of a 2002 FZS600
« on: 01 March 2018, 04:26:26 PM »

SOLD

Givi Monorack arms & plate with all bolts and other parts, comes with integrated amber LED strips for turn signalling. Just missing the box as the bike never came with one, I used it for strapping bags to it for traveling but have now modified the bike just for city running so it had to come off.


It was on a 2002 FZS600 and I have no idea how long it's been on there, it's a solid piece of kit and will be sold on best offer.


Ideally it would be picked up because of the size and weight, located in east London, Plaistow



8
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 06 October 2016, 06:39:42 PM »
Well I checked the slides, the membranes and anything else just in case before putting the "new" carbs in.

But it would be an easy job to swap them for the older ones to rule it out I guess.

I'm inclined to try another ECU, does anyone know if I could use with ease from the same model and if it has to be the same year?

9
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 06 October 2016, 05:46:53 PM »
Update and a surprising twist!

So after my last post I got a second hand set of 2002 carbs. They were filthy on the outside and had gunk and cracked o-rings on the inside. Went through the carb fixing process again and slapped them on the bike.

The engine idles much better! I was so happy! Went for a ride and discovered that now I have a problem in the high RPMs, WTF!?!

It behaves like a ignition retardation when trying to overtake quickly. The engine sputters and looses power of the throttle is twisted quickly. But if I ease it in slowly then I can get through the whole range. I've swapped the TPS sensor (but they're both used) and there's no change. There are new plugs, new caps and the spark looks good.

What's going on!?! Has anyone had any issues with the ECU?

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FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 03 August 2016, 10:53:44 PM »
The Fazer carbs really shouldn't need any tweeking. If I was you I'd put everything back to factory settings. Or for the sake of an easy life just get another set of carbs. They aren't very expensive


Yeah I've done everything I can because I wanted to find the problem. The bike has been to two shops without good results hence me still working on it. Few weeks ago I thought about a set of second hand carbs and tonight after having set the fuel level almost perfectly and the bike still idling like a retard I've decided to formally give up and get another set of carbs!!!  :'(


I spotted a nice set of 2003 version, they should be compatible with the 2002 bike, right?

11
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 03 August 2016, 02:49:11 AM »
So did the bike come to you with these problems, or did they develop while you've had it?



It hasn't been idling very well after a rusty tank incident. Carbs have been cleaned, floats leak tested, O rings replaced, and new needle valves fitted. After a lot of struggle adjusting the fuel level it seems to have changed over a period of few months and sometimes the valves don't seem to be closing properly as the level is randomly too high. The new needle valves have a harder spring, bigger rubber needle and the seats have a bigger hole and are marked 2.0 instead of 1.0 like the old ones. Apart from the obvious differences they seem to be same. My logic thinking tells me that a harder spring would make it easier for the floats to close them but maybe I'm wrong. I did a leak test with the bowls off and not a single drop of fuel was spilled. But when adjusting the fuel level I had to bend the tangs on the floats quite a lot towards the valve to be able to obtain a "useable" fuel level.Does anybody have experience of these aftermarket needle valves? Or any other brand? Here's a link http://www.ebay.co.uk/itm/CARBURETTOR-FLOAT-NEEDLE-VALVE-WITH-SEAT-YAMAHA-FZS600-FZS-600-FAZER-98-03-NEW-/272231399564?hash=item3f6241808c:g:zmEAAOSwqv9V6uV1

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FZS600 Fazer / Float Needle Valves
« on: 03 August 2016, 02:46:11 AM »
Hi there!


I've got a 2002 FZS600 with (30K miles) that hasn't been idling very well after a rusty tank incident. Carbs have been cleaned, floats leak tested, O rings replaced, and new needle valves fitted. After a lot of struggle adjusting the fuel level it seems to have changed over a period of few months and sometimes the valves don't seem to be closing properly as the level is randomly too high. The new needle valves have a harder spring, bigger rubber needle and the seats have a bigger hole and are marked 2.0 instead of 1.0 like the old ones.


Apart from the obvious differences they seem to be same. My logic thinking tells me that a harder spring would make it easier for the floats to close them but maybe I'm wrong. I did a leak test with the bowls off and not a single drop of fuel was spilled. But when adjusting the fuel level I had to bend the tangs on the floats quite a lot towards the valve to be able to obtain a "useable" fuel level.


Does anybody have experience of these aftermarket needle valves? Or any other brand?
Here's a link http://www.ebay.co.uk/itm/CARBURETTOR-FLOAT-NEEDLE-VALVE-WITH-SEAT-YAMAHA-FZS600-FZS-600-FAZER-98-03-NEW-/272231399564?hash=item3f6241808c:g:zmEAAOSwqv9V6uV1

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FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 02 August 2016, 11:07:44 PM »
2 further thoughts:
1. You did tighten the needle valve seat retaining screws when you changed them?
2.Float height for 2000 on models should be 3.5mm above float chamber mating surface ( Its 4.5mm on earlier models) 2000 on carbs are marked 5DM1 01
Earlier models are 5DM1 00.
Only mention this in case carbs have been replaced by previous owner. I know its a bit of a long shot but in diagnosing faults you cant assume anything. :eek
Dont mean to teach anyone to suck eggs but it seems you have ruled out a lot of the obvious things mentioned by others. Good luck!


1. Of course I did and last time I opened the carbs I took the floats out and checked if the needle valve seats were sitting in it's place properly
2. According to the markings on the side these are the correct carbs but it's true, you can't assume anything when you buy a used bike without any history at all

14
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 02 August 2016, 04:46:26 PM »
Dont know if this helps but I recently ordered 4 carburettor overhaul kits from M & P direct. They came in packaging showing maker "Tourmax"made in Japan suitable for FZS 600 1998-2001. ref no 7245384 Vergaser (German for carb) Rep STZ CAB-Y73. Cost for four inc p&p £42-95.
Fitted fine & bike running well. Cant say I noticed any markings on actual needle valve assemblies but my eyes are as old as the rest of me-dont ask! I can understand variation in size of main,pilot,starter jets but why would there be a need for different sizes of the needle valve?
Sounds like you have an over supply of fuel on 2 carbs-maybe recheck condition of "O" rings,floats, & float heights on offending carbs.


The only reason I could think of is to get a faster fuel flow when racing, if the throttle is pretty much wide open most of the time then the bowls would fill up faster with the bigger needle valves. The "O" rings are just a few months old and fine, the floats have been left submerged in fuel and came up without a drop inside so they don't seem to be leaking, the tangs on the floats are bent way much to my liking and compared to how they were originally.


I remember that it was a massive pain to get the fuel level right, both with the original and the new needle valves. One minute I almost had it and after a minor adjustment it changed drastically like something was leaking. Could there be a crack in the carb body?

15
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 02 August 2016, 03:15:19 PM »
A small update but maybe the culprit has been found!


Since I just finished 30K and didn't get the bike's history when I bought it I decided to rule out the valve clearance. When I got the bike it had 22K on the clock and I had no idea if the clearance was checked or not. So on Sunday I decided to open up the engine and check, all measurements well within specs and timing markings spot on so that has been ruled out.


During the weekend I took the jets out and soaked them in carb cleaner over night, I also took the carbs to a local shop and used an air nozzle connected to their compressor and blow out all the passages because so far I've been used canned air but obviously provides less air pressure. Nice air flow through all the passages.


After a night's worth of soaking in carb cleaner I still noticed dark spots on the outside of some jets so I decided to soak them another night but this time in Pepsi. Next morning the jets were amazingly shiny!  :D  My intestines must be super clean as well, haha!


Very happy with my new inexpensive carb and stomach cleaner I put the carbs back together, added some fuel and realised that the fuel level was all over the place!!!
I haven't touched the tangs on the floats since the last time so WTF was going on?!? I opened up the carbs again, bent the tangs all the way up (towards the needle valve) and still I would have way too much fuel on carb 1 & 3


When I took the carbs apart for the second time few months ago I replaced the O-rings and the needle valves. They were aftermarket ones as they were much cheaper but the holes were much bigger and they were marked 2.0 rather 1.0 like the originals. Are they faulty then or is the size of the fuel inlet holes too big for the floats to handle? I wouldn't imagine the size would matter, does anyone have experience of these?
http://www.ebay.co.uk/itm/CARBURETTOR-FLOAT-NEEDLE-VALVE-WITH-SEAT-YAMAHA-FZS600-FZS-600-FAZER-98-03-NEW-/272231399564?hash=item3f6241808c:g:zmEAAOSwqv9V6uV1

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FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 02 August 2016, 02:36:24 PM »
Gotta remember the age of these bikes so unless you buy new then all carbs are gonna look grubby, it's what's going on inside that counts though.

For the record, a new set of carbs is £611, but you do get a free delivery  :lol


Yeah that's exactly what I'm afraid of, the inside could be worse than the outside! Green accumulated petrol gunk  :rollin


That's very kind of them, FREE DELIVERY!  :D  It would be the most absurd thing I could do as the bike costed less than that! It was a salvage bike which I bought as a project bike, was about to finish a big mod when the running problem accrued and it has delayed the works for the whole summer as I don't have the heart nor time to continue until I sort out the heart of the beast!

17
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 29 July 2016, 02:02:39 PM »
How much does utrasonic cleaning cost?
With the pain you're going through i'd be inclined to consider either handing it over to a pro with the bike and let them sort it, or even buying a used set of carbs.
I know that's not ideal, especially if you prefer to do stuff yourself and don't want to be beaten by it, but i'm personally too impatient and would want it sorted asap.


I dunno where you are but i've always given my bike to these lot when i've had carb/running troubles, not cheap but they certainly get the job done properly while you wait.


http://pdq1.com/services/


http://www.ebay.co.uk/sch/i.html?_from=R40&_trksid=p2050601.m570.l1313.TR0.TRC0.H0.Xfzs+600+carbs.TRS0&_nkw=fzs+600+carbs&_sacat=0



Yeah I like to do stuff myself since I can do a good job but I haven't done many carbs. I understand how they work but I prefer much more electronic injection as it's more reliable and you can do a custom mapping instead of painful jetting.


I'm rarely beaten by mechanical things but last month I gave up on this and took the bike to a shop for carb balancing as I thought that might be a solution but the bike came out worse and was drowning in fuel, you could just smell it. I wasn't very happy and obviously took it back but now it's just back to how it was, waste of money that was.


Used set of carbs is something I have thought about already but they all look so filthy on eBay so it would be just another cleaning job and probably a risk of getting a carb that is in a worse state than mine.


I have almost totally lost my patience on this so I called PDQ (thanks for the suggestion) and they are booked until the third week of September! I had a long chat with one of their guys though and he confirmed my suspicion about the passage that lies beneath the pilot jet. He didn't recommend ultrasonic cleaning though, old school elbow grease is much better he said. He recommended getting a nylon wire or something small into the passage, give it a scrub with carb cleaner and blow it out. Hopefully that is going to save my mentality!

18
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 29 July 2016, 12:26:43 AM »

So I managed to spend some time on the carbs today, too much for my liking as I'm going nuts over this. None of the jets looked blocked but I sprayed everything with carb cleaner, let it soak for a bit and then blew through all the passages I could find.


This didn't change a thing, the engine idles like a sick dog. Could the passage for the pilot jet be clogged, what's the best way to clean it? Since the carb cleaner didn't work is the ultrasonic the only way?


Where can I get ultrasonic cleaning, do most work shops provide this service? Doesn't the whole carb need to be submerged in order to ultrasonically clean the passages?

19
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 28 July 2016, 12:23:17 PM »
I didn't read all the thread so this might have been suggested already but you said the initial problem was a rusty tank? Did you treat the rust in the tank? Or did you solve why it was going rusty in the first place? Was there water getting into it? You might have more water in there or more rust has got through clogging up the pilot jets. I think there's a filter in the tank too did you clean that? And did you replace the inline filter? If you've had rust problems in the past I'd be leaning towards a fuel supply issue than a spark issue


Yes the rust was treated and a new inline fuel filter fitted, the fuel looks very clean so far. There's a filter in the tank, where the hell is that? This is definitely a fuel problem and I'm leaning towards the pilot jets as it's only in the lowest of RPMs. Has anyone had to replace them?

20
FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 28 July 2016, 04:50:52 AM »
It sounds like it doesn't run on all 4 when idling and in low RPMs, but mid range and top is great. It passed MOT today and since I was at the shop they checked the temperature on each cylinder, 3 & 4 are running much cooler than the rest.


That's just how mine was running up until a few weeks ago (except it was only cooler on down-pipe number 3).

The workshop did an ultrasonic clean of the carbs and also fitted a new set of spark plugs.

Apparently the main culprit was a blocked primary jet in number 3 carb.


I have changed the plug caps which didn't make a difference but at least now I'll know I won't get a misfire from there. While I was at it I took the plugs out and #4 was a tiny bit whiter than the rest. If I recall correctly then that's a sign of a lean mixture.


I think I will finally find some time tomorrow to rip the carbs off once again and inspect those jets. They have been cleaned with a carb cleaner twice already and air did flow through them and the channels in the carbs.


So could there be an accumulation of dirt that formed some kind of a lime scale that could make those narrow channels even smaller to a point of being too narrow and the only way to clean them out would be by ultrasonic? Was it the cleaning of the jets or the cleaning of the carbs that solved the problem?

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FZS600 Fazer / Re: CARBURETTOR Problems In Low RPMs
« on: 22 July 2016, 02:56:02 PM »

wait for it dark then spray some water over the ht leads and cap and see if you can see very small sparks if you do then you need to change them hopefully it will be the caps if not new or second hand set off coils 



Thanks for the tip, I will check this tonight.

As above, new spark plugs and/or caps will likely sort that. Cylinders 3 & 4 are usually exposed to the elements if your bike spends anytime outside on the side stand. Spark plugs corrode, and a build up of dirt, water and corrosion around them doesn't help.



The bike has been kept inside for the last year, the year before it was outside but on the centre stand and usually with a rain cover. But it probably had it's share of exposure to the elements since the #3 spark plug was stuck in the cylinder head. Several months of soaking it in WD40 and working it back and forth did the trick. When the carbs were put back in for the second time new plugs were fitted. I'm definitely going to check the caps and the leads!


Firstly you've not mentioned the air filter at all, when was it last changed and what type/brand do you have?
If the bike can't breathe properly then it will affect the idle and lower revs, but can also hold you back at higher revs if it's particularly dirty.
Have you even looked into the airbox, it could be clogged up with emulsified oil as well, which my bike has had before.


As mentioned are the HT leads and caps okay?
You can trim the ends off the HT leads by 5-10mm, and maybe try new plug caps. Don't bother with new OEM ones as the price will make you fall over, but a lot of us have replaced them with NGK ones which work fine and are a great price.
http://www.ebay.co.uk/sch/i.html?_from=R40&_trksid=p2050601.m570.l1313.TR0.TRC0.H0.TRS0&_nkw=SD05F+&_sacat=0


A carb balance by the way will only work well when everything else is running properly.
So if your air filter is clogged (or you have an air leak), your TPS is breaking down or knackered, or your spark plug caps are on their way out then a carb balance will be irrelevant and can even make things worse.
Even the TPS positioned wrongly can make the bike feel a tad jerky at lower revs, i would do a check on that too, i'm on my 4th one now although this time i bought a brand new one at a much lower price than over here from Germany as it was all getting a bit silly buying used ones that were at least 13 years old and likely to peg out at any time.
http://www.ebay.co.uk/itm/Drosselklappensensor-TPS-101-Yamaha-FZS-600-DROSSELKLAPPE-13550-13D60-4HD-85885-/361403667980?hash=item542556560c:g:svIAAOSw2s1UxgsX



I did check the air filter, it was a bit dirty, not too much though and I managed to shake and brush away most of the dirt out, I put it back in because I didn't have a new one at the time. The box is clean but the small breather filter had some gunk in it which I cleaned out. Rubber inlets are intact. I'm gonna get a new air filter just in case, should I get the OEM one like the one I have or should I go the K&N route? Or is the high flow of the K&N going to screw everything up more?


Thanks so much for the link to the plug caps, they are at a great price! I did notice though that they don't have the 45 degree (more or less) elbow but I guess you didn't have issues with that since it has been done many times.


I checked the position of the TPS with the speedometer, it showed a tad over 5000 RPM so I twisted it back on forth and made it land on 5000 but theres a lot of leeway on both sides before the RPM needle drops up or down. How can you tell if the sensor is failing? You mentioned that you're on the 4th now, did you measure the resistance in the faulty one when replacing it with a new one?


Last but maybe fundamentally not least, the last fuel level measurement showed that carb #3 & #4 have about 1mm higher fuel level, could this tiny difference cause all this uneven running? Like I mentioned initially, cylinder #3 & #4 are running cooler that the rest, what's the logic here, is it because they don't get enough fuel or is it because they are getting too much fuel? Gonna check the spark plugs for colour later to get some indication.


Thanks for all the replies!

22
FZS600 Fazer / CARBURETTOR Problems In Low RPMs
« on: 21 July 2016, 09:59:39 PM »
Hello everyone!


I'm going bananas over a carb problem in my 2002 FZS600. The engine idled perfectly but had power retardation in the top gear when overtaking. The carbs have been taken apart twice now, the first time to be cleaned out because there was rust in the tank. All the jets and passages cleaned and blown out. The bike didn't run the same afterwards so they were taken apart again, o-rings and needle valves replaced, floats tested for leaks, fuel level set, carbs balanced by a shop but still the bike doesn't run properly!


It sounds like it doesn't run on all 4 when idling and in low RPMs, but mid range and top is great. It passed MOT today and since I was at the shop they checked the temperature on each cylinder, 3 & 4 are running much cooler than the rest.


What more can I check/replace to make my baby run smoothly again???

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