FZ600 Resto - the hotrod XJ

Doh!

 

Mutch better that than needing to do more work.

 

Oh you don't know how happy I am. Much better to be a bonehead with a working bike than a frustrated troubleshooter loosing sleep. I was just testing you guys, everyone pointed to fuel starvation one way or another.
We sometimes overlook the obvious after we've had them all apart, so easy to 2nd guess myself.

 

Nooooo way, eh!!!!!!!!!

 

Canadian, eh?

 

In the RCAF, that's referred to as the Rubber Mallet Award

I know Ontario traffic. Scary bunch. Glad you made it okay and were able to solve the issue.

 

It is a section of the 401, better known as the "Indy 401".
The speed limit is posted at 100 kph, if you actually drive that speed you better have a ramp on the back of your car.

 

I was on the 407 a couple of years ago. Pretty much 120-140kph most of the way. Next to no traffic that morning. Got a bill for $77 about a month later! (automated toll setup on that express road)

 

Over the last year the FZ developed a gas leak through the petcock and through the float valves.
Not surprising as I tried to make some old carb parts work by polishing them with a q-tip in my drill.
It worked for a while. The petcock was another used item I had on hand, slapped it into service and it worked, for a while.
I replaced the fuel pipe O-rings and throttle shaft seals, did everything but skimped on the float valves, Scottish heritage.
Yesterday I devoted another day to the FZ resurrection, planned to replace the float valves and rebuild the petcock.
I drained all the contaminated oil from the motor, recently #1 intake valve must have been sitting closed because the intake tract was completely flooded with gas, I blew it out with compressed air.
I pulled the carbs apart and installed the brand new float valves, noticed the dry setting was close to the manual (20mm) and proceeded to the wet set.
I ran out of Sunday trying to get these things to seal, very frustrating. I even tweaked them all higher with about 22 mm dry set hoping to put more pressure on the valves. After the 4th wet set attempt I gave up.
I think they are K&L, made in Japan. I'm going to pull them back out just to make sure there isn't a piece of crud preventing one of the o-rings from sealing around the outside.
Never did get to the petcock.

 

I'm with you, Simmy. Isn't it amazing what a little time does to the important bits? I always seem to forget, thinking that my XJ should startup like the proverbial Toyota Camry. But then a carb float sticks open, or a petcock hose starts leaking while lifting the tank for a minor carb adjustment, and I have to go cut a new length of hose to install.

The carb stuff seems straightforward, but there are definitely nuances that make me scratch my head.

My last carb rebuild has lasted me 10 years, and I even remember using <gasp> petroleum jelly on the throttle seals, so I'm due for a complete overhaul. I can feel it in reduced performance.

 

I took all 4 float valves back out and inspected the o-rings and the holes they each slide into.
I can't get this any more perfect so I've eliminated this as the issue.
I prepared everything for wet setting. With the carbs still dry I opened each drain site tube
and then filled them up. I could easily see all of them shut off except #2, pic below.
So next thing I'm going to do is inspect #2 float itself. It has to be catching up on the hinge or against the bowl somehow.
I have 8 spares so I'm going to replace the float anyway.
These old bikes are not for the impatient.

 

I don't know about that-- I think my FZX Fazer 700 would be.....

 

Same pistons as an XJ700X so I guess we can accept that one to

 

Basically the same engine

 

I finally got #2 to stop overflowing. Actually changed the float from a spare carb and still found it overfilling.
Drained it empty and tapped it during the next fill and finally got to stop. Wet set measurements were all pretty close, good to go. The nice thing about the FZ is the airbox goes on after mounting the carbs.
Felt so good about this I gave it a new oil filler cap from one of my spare engines.
Now on to the petcock rebuild. I have other bikes to winterize and this thing was sure a pita.

 

I have 2 petcocks. The 1st pic is the one that was just on the bike and it was leaking.
The body where the small o-ring for the diaphragm needs to seal is buggered,
I tried to capture this in the pic but it's not clear, aluminum is smeared in a gob, someone tried fixing it, unsuccessfully


This pic is the original one which came with the bike. you can see it is much nicer.
I replaced it because the nipple attaching the fuel came out of the body.
I stuck it back together for mounting the tank but it eventually leaked.
I swapped it with the spare above.





The elbow nipple has a very tight fit into the body. The groove looks like it might hold an o-ring but the fit is really tight.
I think you would have a difficult time squeezing an o-ring there the fit is so tight.
I think it is meant to press together with just close tolerance.
Anyone know?
I'm thinking if I just smear the connection with something it will hold it.
The petcock is perfect except for this.

 

Without anything to hold it captive, oring or not, it would have to be just a press/interference fit. At least that's my thoughts on it

 

Agreed, I need to smear it with some thing that will stand up to gasoline. Fill the groove. What though?

 

Would some tank sealant work? They sell this stuff at parts stores in a tube like TV silicone that's supposed to seal against fuel. Have heard mixed reviews though

 

I have some but it might be too thick to work.
As long as it remains in the groove it might work