Upstate NY - FJ Refresh

[imagelessJAKE]

So I got the bike fueled up and running! took it out for a quick ride around the block and....

Fuel starvation! I guess the lines are old so even when they are routed to their natural positions using the curvy bit it kinks the line significantly...

Though while it was running? phenomenal power for the size of the thing!

I was very surprised how nimble and light the bike felt while on the road. For my small 5'6" 150lb frame it worked rather well! I can nearly flatfoot the thing.

Very excited for this to get sorted and on the road again!

[Motofun]

If you think you have the lines properly routed..........make sure your tank is venting OK.  Other possibility is the floats are too low so that they shut off flow too early.  My 36 YO FJ still has the original hoses and they work.

[imagelessJAKE]

If you think you have the lines properly routed..........make sure your tank is venting OK.  Other possibility is the floats are too low so that they shut off flow too early.  My 36 YO FJ still has the original hoses and they work.

I only can guess that because when I lifted the tank off to take a look I saw it visibly kinked pretty bad.

I tend to do the easiest thing first - so fuel lines - then if the problem persists I might yank off the carbs and do a rebuild - or send them off.

[fj1289]

Easiest to check tank venting - as long as the tank isn't completely full - try riding with the cap just resting in place, not latched down and see if it helps.  You'll probably want to be down to 2/3 or 1/2 tank before going WOT in lower gears to keep from sloshing fuel everywhere!

[Pat Conlon]

Jake, follow this fuel line route exactly:



http://www.fjowners.com/index.php?topic=18286.0

[imagelessJAKE]

Jake, follow this fuel line route exactly:
http://www.fjowners.com/index.php?topic=18286.0

Thanks! This a huge help - my line from the petcock runs above the loop - not below like yours - the kink is located at the apex of the loop (I think maybe because its not stock and might be cut too short)

Good news is the bike is venting well - I blew on what I thought was the breather tube on the back of the tank (facing towards the rider) and heard air pushing through the gas cap

[Pat Conlon]

.....Good news is the bike is venting well - I blew on what I thought was the breather tube on the back of the tank (facing towards the rider) and heard air pushing through the gas cap

FYI, that's not a vent line ^^^ that is a drain line. All the FJ's with recessed fuel caps have this drain line.
The purpose of this drain is to capture any spilled fuel in the recessed portion of the fuel cap, then by gravity, drain it out of the recess and out the drain line.
This drain is on the exterior of the fuel cap seal and has nothing to do with the internal venting of the fuel tank.

I think your troubles will go away when you have the fuel line routed correctly.

Report back with your findings.

Cheers. Pat

[Old Rider]

You can also make a spring out of steel wire (or buy a suitable spring )   that will eliminate kink when line gets hot .

[imagelessJAKE]

You can also make a spring out of steel wire (or buy a suitable spring )   that will eliminate kink when line gets hot .

I had a similar idea! I've used this trick before on some odd bends and curves in the routing.

While I'm waiting on some new braided fuel line to show up - my new bellypan has arrived from the UK!

It looks great! much better then the old one! I've ordered some gold heat wrap to line the interior so hopefully it will limit heat cracking.

Graphics from RDDecals are gonna look phenomenal on this piece.

On some of the side panels - some of the plastic pins/clip pieces that fit to rubber grommets have been snapped off - has anyone found a solution to replacing the pins/clips?

[Old Rider]

The fuelhose spring is oem on many bikes  Suzuki rg500gamma  is one of them. I bought same spoiler as you from UK it is very good quality i painted it in Lexus starfire pearl white because all the rest of the white on bike has that color i painted the orange and black to because rest of bike has same orange.Painted straight on the gelcoat just rubbed up the gelcoat first
Used heat protection mats inside haven't had any heat bubbles in the paint where the lower parts almost touches the exhaust.Had it on for 2 years i think
I have used small spacers cut out of fuelhose on the 2 rear screws so it get a little distace from exhaust

[imagelessJAKE]

Hey all!

So the new fuel line routing seems to work! No fuel starvation and it idles steadily with no choke needed.

It doesn't sound too great though - somewhat choppy and poppy like a lawnmower - to me it could either be running lean/rich - the carbs could be unbalanced - or my old rusty exhaust could have leaks. I'll be doing some investigation into the matter

Right now - I am happy the thing runs and smoothly!

Pictured below: The old fuel line that came off the thing - not in the best of shape.

[imagelessJAKE]

Folks, it finally happened!  

Was able to take the FJ on the road and go through the gears fully in a roughly 4 mile gauntlet with plenty of turns - With a bit of smoke and pop (I think it might be the oil rings setting in after so long)

all I have to say is that I am blown away by the speed - if my speedometer is correct - 45 in 3rd with very little throttle.

The handling is very easy for a bike of this size (I am of smaller frame) I easily fit this bike in both an upright position and a tuck.

Blown away!

Please excuse the dorky mirrors - I ordered them from the UK and... well I dont think they were meant to fit a US bike

FYI - The bellypan is off with the painter so he can replicate the graphics position on the new one

[FJmonkey]

Maybe the mirrors need to swap sides?

[imagelessJAKE]

Maybe the mirrors need to swap sides?

This was my first thought - however after switching them, flipping them etc etc they still look awkward an alot more vertical then they should to me.

I replaced them because the originals were a bit nasty and had some corrosion and chips on the glass. I might look into just getting new mirrored glass popped in.

[FJmonkey]

Ok, they must be for 89+. You need a wedge of sorts to tilt the base. I made proper wedge bases but before that I stuffed a screwdriver bit under the base with working results.

http://www.fjowners.com/index.php?topic=1562.msg34868#msg34868