Hello everyone,

[kreulach]

Just picked up a 1990 FJ1200 last week. I'm in Bentonville Arkansas and have been riding for about 28 years. Previous bikes were Maxim, Radian, Helix, ZZR 600, CBRR 954 and an 87 Goldwing Aspencade.  The previous owner of this FJ1200 had fuel issues so he threw away the stock fuel pump and bought a knock off on ebay that leaks around the middle of it. Bought another one and had same problem, so he gave up. He cleaned the carbs, but it still ran rough, so I took the carbs apart and found two of the pilot jets were clogged. New fuel pump for this bike cost 9 million dollars, so I got a weird fuel pump from ebay that has the inlet on one side and outlet on the other instead of both on the front. Now the fuel pump is not leaking and the bike is running right, but there is fuel dumping out of the hose that comes from some kind of solenoid looking device under the carbs that has two hoses going into it from the carbs and one hose going out of it that is routed along with the float bowl drain lines. Not sure if it is supposed to be connected somewhere else, but I simply put it back where the last owner had it after he tried to rebuild the carbs. Sure would like a service manual for this thing so I can make sure everything is routed correctly. I attached pictures of all the aforementioned items. Any tips would be appreciated.

[Country Joe]

Welcome to the digital campfire, kreulach! I think  that it's only right that I might be the first to welcome you to the forum, seeing as I am probably the closest member here that has owned a 1990 FJ. I live in Clinton, AR, we've been here since 2008
As far as your fuel leak goes, I would check and see how much pressure that new pump is putting out. I don't recall any solenoid under the carbs on a 1990, but I'll grab my manual in the morning and make sure I haven't forgotten something.

Joe

[FJmonkey]

My '89 does not have any fuel lines routed under the carbs to connecting to devise like you mention. Is their a filter under the tank? Or could it have been moved and that is a fuel filter.

[kreulach]

Thanks for the replies, Country Joe and FJ Monkey.

Joe, are you planning on coming out for bikes/blues/BBQ this year? If I get my FJ running we can meet up. The fuel pump maybe putting out too much presssure or it may not stop pumping due to backpressure like the original. I saw a test on youtube that I will try out in the morning.

FJMonkey. The weird thing below the carbs has two wires going to it, but I'm not sure what it's purpose is. I think I'm going to try to bypass the fuel pump and just run it on gravity feed and see if it still leaks.

I also found on the forum that a fuel pump from an early 2000's R6 or a late 90's YZF600 will work. I've found these on ebay for under $50, so I may try one of those after I do a couple tests.

[Alf]

Welcome to the community

There are a lot of cheap OE fuel pump repair kits at eBay. I think it is the fastest and better solution.

Send me your email and I can transfer you a manual

Regards

Alf

[FJ_Hooligan]

If the 2 hoses plumbed into the solenoid looking thing are from the carb float bowl vents then I think it's part of a California emissions system.  The output used to go to charcoal canisters which were mounted on the frame rails in front of the engine. 

If you have fuel leaking from there, then your float level may be too high.

Or, the fuel pump may have too much pressure and that's causing fuel to leak past the needle/seat shutoff.

Jump around the fuel pump nd use gravity feed to see if the leak stops

[Country Joe]

Kreulach,
FJHooligan is spot on with the comment that the solenoid is part of the evaporative emission control system. My 1993 does not have anything on the bowl vents but rubber tubes long enough to hang down below the engine. You can take the solenoid and canister off your bike to simplify your trouble shooting but you will have to plug the port that sucks the vapors from the carbon canisters into the intake to avoid a vacuum leak.
I hadn't planned on going to BBBBQ, but if I can find out which manufacturers are going to be there for demo rides, I may have to come up there to sample some new bikes.
Joe

[FJ_Hooligan]

We like to go to Arkansas during Bloops, Bikes and BBQ or the big Music fest on the Pig Trail at the top of the mountain.

Perfect weeks to ride the mountains everywhere else since EVERY state trooper is stationed at those 2 events.

[kreulach]

Thanks Hooligan and Joe for the canister solenoid info. Sounds right since the hoses going into the solenoid are plumbed to the bowl vents. When I tore into the carbs after the previous owner, I noticed he replaced two of the float needles and they had enough spring power left in them to lift the floats when the carbs were turned upside down, but the old needle springs let the floats collapse. this would explain the high bowl level. I'm just going to stop being cheap and get a complete rebuild kit for the carbs while they're still easily accessible.

[Country Joe]

Good point about the BBBBQ weekend, David. Last year I ran Push Mountain Road 3 round trips on the Saturday during BBBBQ, I saw less than 8 chrome plated chicanes the whole time I was up there.
BTW, there will be a group, usually around 8 to 10, from the FZ1 owners association on the weekend of October 6-8. Its a really good bunch of guys to ride with. If FJHooligan, squidley63 from Booneville and you can make it then, we can represent FJOwners in a mini-rally contingent. Now all I gotta do is keep my paws and wrenches off my FJ between now and then.
Joe

[kreulach]

Pencil me in, Joe. If your paws and wrenches are eager to tear into an FJ, mine is calling your name. LOL.

[aviationfred]

   Welcome to the forum. It is a good idea to rebuild/repair all 4 carbs at the same time. Repairing a single carb often leads to other problems.



Fred

[Country Joe]

Pencil me in, Joe. If your paws and wrenches are eager to tear into an FJ, mine is calling your name. LOL.

That is a distinct possibility. I'm already committed this Saturday, but I will PM you and set up a time to help you out.

[FJ_Hooligan]

Joe,
Our current plan is to be there during the first week in October.

Any chance you'll be available that week?

Although it would be nice to show up on a coupe of FZ1s, especially a Bumble Bee! Which I've started calling the Bumble Z.  :-)

[Country Joe]

Joe,
Our current plan is to be there during the first week in October.

Any chance you'll be available that week?

Although it would be nice to show up on a coupe of FZ1s, especially a Bumble Bee! Which I've started calling the Bumble Z.  :-)