2009 fz6 starting troubles

[TownsendsFJR1300]

One hose nipple I believe, is attached just below the filler cap(it internally has a steel line running up inside the tank)... If when fueling, the fuel makes it up too high, the fuel will run out that opening/filler/hose instead of down the tank. If the tank is very full and left in the sun, the fuel will expand some and again vent/leak out the overflow..

The other nipple should be for strictly venting the tank. If it wasn't vented obviously, you'd develope a vapor lock.

You can blow some air (doesn't need to be alot, 10PSI) thru the lines to make sure their clear... IMHO, I would disconnect them at the bottom of the tank, blow out the hoses downwards, and for the tank itself, upwards..

Pic's are from my old 07 tank, about 1.5 years old..

 

[hybriduff]

Ok so I figured out the REAL problem!

The pic attached is from the post above me. When I took the tank off and inspected the inside it looked ok BUT I saw a visible specs of rust/debris floating around in the last little bit of gas in the tank. In an odd fashion, I plugged the overflow hole on the top of the tank, and blew through the overflow nipple on the bottom of the tank and air was leaking out from a rusted spot in the line! I used some JB weld to cover the small hole and essentially plugged off the overflow nipple, and siliconed the overflow on the top of the tank (so water doesnt get in there and rust the line again). The breather line was okay.

Now the bike is having the same issues as before (wont fire up), except i'm certain that I just need to clean the filters and lines thoroughly. No more gas leaking though, that's nice...

 

[hybriduff]

And also...where is this filter, and how do I clean it? I searched all over the internet and on this forum for a description but i have to see a good explanation

 

[FinalImpact]

Filter is on the pump inside the tank.

One has to wonder if the products used JB and silicone came free and plugged something up as neither are meant for use in contact with petrol.

There used to be some real good close up pictures of a pump and filter but I'm not sure they are still up. You should replace that tank or use products that are meant to be in contact with fuel. ** GAS FIRES ARE NO FUN ** and its not like you get a second chance.

 

[hybriduff]

JB weld says on the website its okay to use in fuel tanks

 

[TownsendsFJR1300]

And also...where is this filter, and how do I clean it? I searched all over the internet and on this forum for a description but i have to see a good explanation

Below are two pic's of the fuel pump. I don't have any pic's of the pump apart, the second picture with the orange writing shows the tab which should be used when removing the pump from the tank. It separates the fuel level sending unit from the pump itself making removal MUCH EASIER. Push the tab in the direction noted, the sender unit slides off. The ENTIRE unit can later be re-installed as one unit..

Once the pump is out you can get to the fuel filter/screen and clean it up... The filter is obviously near the base of the unit. As I recall, its about 3" x 3" or so.

I'd blow out the tank real good being its apart too..


Looking at the shop manual, I don't see any drain for the fuel rail. About the only way to check/clean it if necessary is to remove it from the engine and fuel injectors and blow it out. The fuel filter does a pretty good job and will clog up but does usually keep the bigger stuff (rust) from getting to the injectors. Varnish, that's a whole different animal...

 

[hybriduff]

When I saw this, all I could do is just smirk and think 'lol'.

BY THE WAY --------- If anyone is considering taking the fuel pump apart like I did.. MAKE SURE IT GOES BACK TOGETHER RIGHT. I was having fuel delivery issues because an o-ring in the pump was loose.

Everything is running fine now. And there's no fuel leaking anywhere. Thanks to everyone who replied and helped out. Mad props. :thumbup:

 

[TownsendsFJR1300]

When I saw this, all I could do is just smirk and think 'lol'.

BY THE WAY --------- If anyone is considering taking the fuel pump apart like I did.. MAKE SURE IT GOES BACK TOGETHER RIGHT. I was having fuel delivery issues because an o-ring in the pump was loose.

Everything is running fine now. And there's no fuel leaking anywhere. Thanks to everyone who replied and helped out. Mad props. :thumbup:

Just curious, what o-ring went bad in your pump? Was that pump from your '09?

Great pic's too, got the first two saved for future reference/posting, thank you..

 

[hybriduff]

No problem Townsends, I've got a couple other shots if you are interested. I can PM them or email. If you look at the second picture I posted it's the o-ring on the bottom of the picture. I'm fairly certain that the main housing didnt not properly seal when I pout it back together and caused the fuel pump to make a 'regurgitating' sound after i tried to prime. It sounded like zzzzzzzzzzzzblooblblbllbl when it was regurging.

PS, yes it'sthe original pump from my '09

 

[Nelly]

If you lifted the tank to jump the bike, did you make sure not to kink any of the vent lines coming off the tank when you set it back down? Also with it starting on the starter fluid did you try to give it some gas once it fired up? If you didn't try it again after you made sure the lines are not kinked and once it fires up give it some gas and try to hold a steady 3-5k rpm for a min or so with no spray. You also might want to try to up you idle a bit.

+ 1 on what Chevy posted.
The year before last the winter here was really bad, I left my bike full of petrol for about 3 months. Like you I just added some injector cleaner.
It ran just the same as it always does.

Nelly

 

[Nelly]

Delighted that you got it all sorted, thanks for posting the pictures.

Nelly

 

[TownsendsFJR1300]

No problem Townsends, I've got a couple other shots if you are interested. I can PM them or email. If you look at the second picture I posted it's the o-ring on the bottom of the picture. I'm fairly certain that the main housing didnt not properly seal when I pout it back together and caused the fuel pump to make a 'regurgitating' sound after i tried to prime. It sounded like zzzzzzzzzzzzblooblblbllbl when it was regurging.

PS, yes it'sthe original pump from my '09

Naw, I can see it there in the picture, pretty unusual.

A whole lot cheaper scrounging up an O-ring vs a new pump too...