yes more leaking carbs

[PaulG]

Hi everyone - just joined up last night.  In my intro I mentioned my carb problems on my '92 FJ1200 and here they are in more detail:

- last winter disassembled and cleaned carbs, put on new float bowl gaskets.
- in May re-installed carbs, started it up and they gushed fuel out all four overflow tubes and the vent holes at the inlets where the air box attaches.
- removed carbs, checked float levels and seemed ok.
- had to take to dealer to get them balanced anyhow, so asked them to check it out.
- they said most probable cause would be worn float needles and/or seats, or maybe faulty fuel pump running too long at start-up.
- if you read my intro you'll know there were many things that were never maintained on this bike by previous owners, so they're assessment seemed logical (to me anyhow...) and I ordered new float needles and seats.
- mechanic checked floats and said they were ok, they installed new needles/seats and it still leaked.
- mechanic bypassed fuel pump and he said it ran fine until carbs were starved.
- once he reconnected fuel pump it started to leak again.
- he said he managed to get carbs set-up ok and was going to test ride it when it started leaking again.
- so they now suggested fuel pump but since my bill had rocketed to $600 I said no thanks and took the bike home.

Most of the things I've read in this forum (including the FJ1200 Carb Leak Advice) and elsewhere have dealt with worn float needles or sticky floats.  Since the needles/seats are now replaced I guess that's not the problem, and I can't see all four floats sticking at the same time (I hope).

Could a faulty fuel pump be the problem?  I found this video on YouTube which demonstrates a faulty vs. new fuel pump for an FJ:

ＦＪ1200燃料ポンプのトラブル：Trouble of FJ1200 fuel pump

I tried this technique with mine and it does run on for a while (10-20 sec?), though I haven't actually timed it yet.  Has anyone out there had any experiences like this with their fuel pump?

I am going to fiddle with it some more and do some more research before I make any decision since a new one is $300-$500!  depending on who I talk to.

If I dare I can get a used one for about $150 with no guarantees it will work.

Any suggestions?

[Harvy]

Paul.......I think its '99-'01 R6 fuel pumps that are the same as the FJ pump (pressure wise), the inlet and outlet pipes are bent thru 90 degrees, but all else is the same.

May be worth a try if you can find a friend locally with an R6 to try it out.

Seems to me you have maybe a crook pump that is not switching off and/or fuel float level problem


Harvy

[simi_ed]

Paul, you probably have bad orings on the needle valve seats.  They WILL leak under pressure.  Mine used to drip fuel out the overflow tubes, then run down the swingarm!  The orings on the fill lines (Tee) between carbs & the vent lines (another Tee) are probably bad as well.  David Raforth (oldslowguy?) has a carb kit that will help you out, for ~$15-20.  Get his kit, follow his instructions, and keep away from the stealer dealer and you'll do fine! 

Good luck

Ed

[racerrad8]

Also, here is a aftermarket pump. http://www.fjowners.com/index.php?topic=228.0

Randy - RPM

[Arnie]

PaulG,

There are a number of "other" fuel pumps that will work just fine on the FJ and don't cost genuine Yamaha stealer ransoms.  see below

However, if your pump is stopping after a few seconds, that is not likely to be your problem.
The back pressure should cause the pump to stop.
Have you tried putting a blocked hose on the fuel pump outlet to see if it does stop?

Just out of curiosity, did the dealer put the correct float needle jets in?  The ones for the fuel pump bikes are much smaller than for the early gravity fed carbs.

I expect that you and/or the dealer have checked the O-rings that hold the float jets in place, right?

FUEL PUMPs   Part No      Pressure Range   Max. Flow
 Brand             
 FEDTRO   FED-40104   1.5 – 3.5psi           28 gph
                         FED-40105    2.5 – 4.5psi     30 gph

       Sold on Ebay.au by       the_auction_broker  (Philip Island)

* FuelFlo        015        1  -  4psi   23 gph  1.5Lpm   
   Repco supplied for A$110.00  (I paid this huge price as I was on a trip and needed it immed)

Airtex -          ES8016S      2.5-4.5 PSI   30 GPH
5/16" hose barbs   It is a solenoid pump that stops fuel if no power

Cheers,
Arnie

[Marsh White]

Paul,

Check out this post:
http://www.fjowners.com/index.php?topic=1147.0

You can find a replacement fuel pump on eBay for cheap.

The 1997-2002 YZF600 Fuel Pump is IDENTICAL to the fuel pump on the FJ.

Also - Randy sells NEW point sets for the FJ fuel pump for $33.00 USD:
http://www.fjowners.com/index.php?topic=69.0

[SlowOldGuy]

Fuel pump won't cause a carb leak unless there is something wrong with the carbs.

You can get a brand new set of carbs from Radny for about $400.  Sounds expensive, but once you start replacing a bunchof carb parts, you'll spend $400 easily and still not have all that parts you need.

Someone (Bill W?) was selling a set for $350.

Wish you had signed up earlier.

DavidR.