still having problems

[4003tj]

Ok i'll start at the begining
I got the bike last aug and it hadn't run for about 18 months, the tank was full of crap as were the carbs, the battery was dead, the fork seals had blown all over the forks, break callipers, rotors and wheel, the screen was bust as was the top left of the fairing where the screen joins, and the clutch lever was snapped as was the left mirror (methinks it was dropped on that side )there was also a hole in the alternator casing where a bolt had been overtightened and taken the casing with it and the exhaust headers were blowing.

The bloke i got it from managed to get it going before i bought it and it sounded sweet as a nut but wouldn't rev up much past about 4 1/2 - 5 thou

job's I've done in no particular order
exup valve has been checked and is ok
fixed hole in alternator casing by re-fabing with epoxy resin
new yuasa gel battery
new clutch lever
rebuilt the top fairing + new screen
new fork seals + oil
new oil filter + oil
new break fluid + calliper strip down and rebuild (pads are ok)
carbs completely striped down and cleaned 3X, checked out the manifold boots but these seem ok, a bit old but not split
tank cleaned with metal treatment, made a couple of plates to go over the tap and fuel gauge holes to stop it leaking, put a hand full of nuts (31 to be precise) in with the acid and then shake and leave, repeat until the desired rust free tank is obtained, rinsed with hot soapy water then the hose pipe then dried with the wife's hair drier, she wasn't best pleased it kept getting to hot and cutting out, cleaned the tap right out, and re-soldered the wire back on the fuel gauge which had come off,

After all this i restarted the beast and it's still the same, sounds great till you rev it up then it's just like it's hit a rev limiter, i tried allsorts but nothings worked until i hit the kill switch one day (i normally used the key) and re-started a couple minuets later and it was perfect, revved right up there, then died back down, hit the kill again then re-started it worked for about another 20 seconds, so i thought the switch was faulty so i bought another and it's still the same so i'm stumped any help would be appreciated

cheers

PS don't know if this will help but i left the battery on the bike last night and this morning it was as flat as a pancake, it had spent 2 months in the shed and was fine 1 night on the bike and it's flat, and yes everything was turned off, in fact there's no headlight or front indicators on it nor fairing as it's still stripped down

[yamaha_george]

Hi,
That PS is the real pointer ! you have ashort in the wiring that is causing the battery to fade & the vibration of a working engine makes it worse to the point of cutting out the engine.

You need to check all the HOT wires (ie those that still have 12v on when you have the ignition switch off (check the ig. switch as they do fall apart internally to the wiring).

take the gas tank false cover off and the airbox . very carefully lift any wiring where it crosses other stuff see if you see any scorch marks from electrical activity.

MOST of all get that battery fully charged ASAP

[4003tj]

cheers george i was hoping it wasn't going to be electrical it doesn't actually cut out it just won't rev up
there's also a bracket on the gearbox casing with nothing in it and a connector with 1 black and 1 blue/black wire that doesn't go anywhere, i'm trying to add pics...
here goes [img][IMG]http://i753.photobucket.com/albums/xx178/hogdigerdy/FZR%20400%20RR%20exup%203tj/th_DSC00004-1.jpg[/img][/img]

[yamaha_george]

cheers george i was hoping it wasn't going to be electrical it doesn't actually cut out it just won't rev up
there's also a bracket on the gearbox casing with nothing in it and a connector with 1 black and 1 blue/black wire that doesn't go anywhere, i'm trying to add pics...

The amount of cuurent available to the FZR is critical , they hate anything less than a fully charged battery (as my brother who is minding mine has just found out DOH I told him to start the bike every other day )

The same is true if there is "leak" along the firing lines for the plugs/ spark coils

As for pictures, thanks for the compliment but my memory is not that good and my eyesight certainly is lacking as the bike is 4080 mile away <BG>

Some one else will have to chip in at this point.....................RR????

[4003tj]

Well i think i've found the problems, as there's two, or so it appears, first off i tested the battery and it's fine then i've tested to see if it's draining with the ignition off and there doesn't seem to be any drain so i scratched my head for a bit then decided to have a look at the ignition as when i got the bike it never came with keys so i had to send the ignition of for a re-build and new keys, anyway the upshot of this was i discovered you can take the bloody key out with the ignition on so i think that's what i must have done and hey presto, flat battery
The other problem is the empty bracket under the tank, it's supposed to have a fuel pump init, so i'm now on a mission for a 3tj fuel pump, and this will hopefully cure the problem

[sweekster]

Here's a silly question...Have you adjusted the exup cables so that when the servo is in "full open" that the valve in the header is the same? If the valve or servo aren't adjusted right then it won't rev as it should. Just a thought.

[4003tj]

time for an update
well where to start, the fuel pumps on it's way but since then i've discovered the starter relay is shot and the previous owner had tried to bypass it by cutting the starter switch out the loom and connecting it to the starter solenoid, which starts the bike but bypasses the starter relay and consequently the fuel pump and the clutch, side stand and neutral safety switches, muppet
so i have fitted a new loom and starter relay and all is working fine, it wont turn over if the switches (clutch,side stand and neutral) are not closed in the right sequence and i now have 12v out the fuel pump connector for about 5sec on ignition, which is as it should be, i also got the exup servo and new cables with the loom so i have fitted them as well.
so when the pump arrives it should all come together nicely, haha where have i heard that before, oh i said it, about 3 times already,
still you never know.....

[yamaha_george]

400,
well at least you are learning about electrics which at first you feared now you are helping others.

So it is not all doom & gloom as for th PO Muppet is probably the kindest words for him <BG>

[4003tj]

Ok so i haven't posted for a while,
so here's an update,
And it's all good
got the new fuel pump and fitted some new float bowl seals and that's sorted that problem and now it's running properly, had it MOTed in early april and it went strait through, just an advisory on the front tyre (that's tyre isn't it geo)
I rode the beast around for about a week and realized i had to do something with the suspenders as it handled like a bowl of blancmange, i managed to get hold of an R6 rear shock with 375 kg spring already fitted (standard R6 being 525 kg) and the adapter to lengthen the shock to the 3tj length to keep the ride hight the same and that sorted the back end out a treat but the front was terminal, it topped out on acceleration and bottomed out on braking and i didn't even have to be pushing it, so a call to maxtons was in order (they really are the dogs, always at the other end of the phone with advice) i now have a set of springs made to my weight and spacers to suit, the spacers were delivered a tad long which worked out just fine as the RR forks are non adjustable so my preload is shaving a bit off the spacer at a time till it's right, at the moment i'm 5mm over recommended length but that's a bit hard so this weekend they'll be cut down another couple mm until it feels just right, but so far the bike rides like a rocket ship and sticks to the road like glue.
I've also done a bit on the cosmetic side and re-sprayed the rear panels as they had some nasty marks where the previous owner had gaffer taped the seat on and knackered the paint, I've also got some goodridge hoses ordered, front and back and EBC HH pads all round so i might even be able to stop the thing,

[yamaha_george]

Ok so i haven't posted for a while,
so here's an update,
And it's all good
got the new fuel pump and fitted some new float bowl seals and that's sorted that problem and now it's running properly, had it MOTed in early april and it went strait through, just an advisory on the front tyre (that's tyre isn't it geo)
I rode the beast around for about a week and realized i had to do something with the suspenders as it handled like a bowl of blancmange, i managed to get hold of an R6 rear shock with 375 kg spring already fitted (standard R6 being 525 kg) and the adapter to lengthen the shock to the 3tj length to keep the ride hight the same and that sorted the back end out a treat but the front was terminal, it topped out on acceleration and bottomed out on braking and i didn't even have to be pushing it, so a call to maxtons was in order (they really are the dogs, always at the other end of the phone with advice) i now have a set of springs made to my weight and spacers to suit, the spacers were delivered a tad long which worked out just fine as the RR forks are non adjustable so my preload is shaving a bit off the spacer at a time till it's right, at the moment i'm 5mm over recommended length but that's a bit hard so this weekend they'll be cut down another couple mm until it feels just right, but so far the bike rides like a rocket ship and sticks to the road like glue.
I've also done a bit on the cosmetic side and re-sprayed the rear panels as they had some nasty marks where the previous owner had gaffer taped the seat on and knackered the paint, I've also got some goodridge hoses ordered, front and back and EBC HH pads all round so i might even be able to stop the thing,

400,
Well at least you have gotten to grips with it and now you know what else you have to do. Get the pads & hoses in place and then it is time to ride.

[4003tj]

oh i've already rode it geo, we generally go out Tuesday and Wednesday evenings for a ride Tuesday being poole quay bikenight and wednesday being a new bike night that's just starting at burly social club, meet at 7ish then go for a ride through the new forest ending back at the club about 9 30, in aid of the Julia's house children's charity,
I went out last Tuesday with a couple of mates for a bit of a spin ending up at the quay, as you do, we went out from poole through corfmullen, sturminstermarshal, blandford, sturminsternewton,sherbornecastelton, shaftesbury, sixpennyhandly, wimbourne then back to poole quay, 165km of dorsets best wiggly bits in about 1 1/2 hours !!!
anyway here's some pics of the machine

[yamaha_george]

Very tidy looking machine,
next week I may be in Poole (sans bike:-{{{{) with the brats wednesday onwards or it might be Exeter happy Families rule YUK