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Project FZR fix up

Discussion in 'Your 250cc Projects' started by Yetiburger, Oct 7, 2017.

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  1. Yetiburger

    Yetiburger Well-Known Member

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    Hi guys.
    I've just purchased a 3ln1. I bought it sight unseen and was a bit rougher than i thought when it showed up (will need to replace pretty much all the fairings) . Anyway I got it to run but it was pretty rough, which I knew when buying it. I have bought the keyster kits and a seal kit from Litetek to rebuild the carbs and get this thing running properly. It has three fuel lines coming from the bottom of the tank, one i'm guessing is the overflow/breather, one goes to the tap and one has be blanked off does anybody know where this line is suppose to go? also could anybody post some links to info on rebuilding the carb?

    20171004_103451.jpg
     
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    Yetiburger, Oct 7, 2017
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  2. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    You will have 2 lines together (the larger diameter lines) which will be for normal fuel feed and reserve... the fuel tap should have 2 inlets to it as well... the other line will be a drain from the fuel filler recess on the tank..
    That is so long as my memory isnt failing me... :)

    Have a look at this thread for more info
    https://2fiftycc.com/index.php?threads/fzr250-3ln1-fuel-system.1804/
     
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    Andych, Oct 7, 2017
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  3. my67xr

    my67xr Bike Enthusiast Premium Member Contributing Member

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    Litetek has guides on it's site for reassembly of the carbs
    Guide to Rebuild Mikuni BDST Carburetor's

    For the fuel tank pickup's,
    the one toward's the front of the tank is for the reserve position, and one toward's the seat is for the On position.
    Reserve line goes to position 2 on the back of the fuel tap, and On goes to position 1.
    O on the back of the tap goes to the fuel pump via the fuel filter
    The sort of pointy end of the fuel tap lever show's what position the tap is currently at

    The long vent line from the tank run's down and through a loop along with the engine crankcase breather tube, the loop is just forward/below the gear selector shaft, the tank vent hose goes back a bit further then exit's just in front of the swingarm
     
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    Last edited: Oct 7, 2017
    my67xr, Oct 7, 2017
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  4. Yetiburger

    Yetiburger Well-Known Member

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    Awesome thanks guys. there seems to be no barb on the tap for the reserve and no thread for for one. can I tap this and put one in or do I need to find a new tap?
     
    Yetiburger, Oct 7, 2017
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  5. Yetiburger

    Yetiburger Well-Known Member

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    Also does anybody know how to get the slide and jet housing out of the carbs?
     
    Yetiburger, Oct 7, 2017
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  6. my67xr

    my67xr Bike Enthusiast Premium Member Contributing Member

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    Slide just lift's up and out with the carby's plastic top cap and spring have been removed.
    Slide housing is held to the carby body by the emulsion tube, you need to undo the brass acorn headed bolt from the jet housing underneath and then you should be able to remove the slide housing, sometime's you need to gently push on the emulsion tube to get the slide to start moving.
    Be careful though the plastic slide housing's can break around the emulsion tube

    What shape is the fuel tap?
    Guessing it look's like this first one below?
    On the first one the barb for the reserve is at the top, it's a pressed in item from the factory, it may have come loose and someone didn't bother to refit it
    They can come loose and leak, or come loose and fall out.


    20171007_183610.jpg

    20171007_183636.jpg
     
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    Last edited: Oct 7, 2017
    my67xr, Oct 7, 2017
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  7. Yetiburger

    Yetiburger Well-Known Member

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    Yeah looks like the first one. Its definitely gone, can you get replacements? Ive managed to get one slide housing out but it was really stuck in there. Put a cap screw in the emulsion tube and gave it a few almighty smacjs with a soft face hammer and it did nothing. Have been trying to gently wiggle the jet housing with pry bars but have only got one so far.
     
    Yetiburger, Oct 7, 2017
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  8. Linkin

    Linkin The Mechanic - Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Try soaking some WD40 or Inox into them.

    As for the fuel taps, I scored a new old stock one from yahoo japan auctions/buyee at a good price. Otherwise try CMSNL but they are pricey.
     
    Linkin, Oct 7, 2017
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  9. Joker

    Joker See "about me" for contact details. Contributing Member

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    I have a spare fuel tap which I can send to you if required, just let me know. Will do you a deal.

    I have never seen one with two fuel lines in and 2 fuel lines out. Mine has 2 in, 1 out.
     
    Joker, Oct 7, 2017
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  10. my67xr

    my67xr Bike Enthusiast Premium Member Contributing Member

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    Both of mine a 2 in, 1 out ?
     
    my67xr, Oct 7, 2017
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  11. Joker

    Joker See "about me" for contact details. Contributing Member

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    I got a bit confused, it sounds like he wanted to tap a second barb into the fuel tap? Is that right? or is the one that was there originally the one that is missing and he wants to replace it?

    When mine fell out, I literally JB welded it (metal epoxy) back in place. Never had an issue since, but it doesn't move anymore.
     
    Joker, Oct 7, 2017
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  12. Yetiburger

    Yetiburger Well-Known Member

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    yeah the original one is missing, so i might just put a brass barb in it and see if that works.
     
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    Yetiburger, Oct 7, 2017
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  13. Joker

    Joker See "about me" for contact details. Contributing Member

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    Yeh I imagine it will be fine.
     
    Joker, Oct 8, 2017
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  14. Yetiburger

    Yetiburger Well-Known Member

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    OK so I soaked the jet housing and emulsion tubes in wd40 for the night but they still won't budge. will let them soak for the week but i have a bad feeling i may need to machine the tubes out. Has anybody else had them this stuck before?
     
    Yetiburger, Oct 8, 2017
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  15. Linkin

    Linkin The Mechanic - Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Use a punch and a soft faced hammer to carefully knock the emulsion tube out - slow and steady, not with brute force.
     
    Linkin, Oct 8, 2017
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  16. Yetiburger

    Yetiburger Well-Known Member

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    ok so does anybody have a jet housing for sale?
     
    Yetiburger, Oct 8, 2017
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  17. maelstrom

    maelstrom LiteTek Premium Member 250cc Vendor Contributing Member

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    I would try heat. Something like out the carb in boiling water.
     
    maelstrom, Oct 8, 2017
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  18. Yetiburger

    Yetiburger Well-Known Member

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    oh yeah I'll try that with the next two. the plastic should be fine that right?
     
    Yetiburger, Oct 8, 2017
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  19. Joker

    Joker See "about me" for contact details. Contributing Member

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    I have had the issue before but not as extreme as what it sounds like you have got. They can be difficult to get out. hot water might help, I'd try that. Shouldn't hurt it. Putting up some photos here of where you are at might also help us give you other ideas.
     
    Joker, Oct 8, 2017
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  20. Yetiburger

    Yetiburger Well-Known Member

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    ok i will try and get some photos up tomorrow. thanks guys i just wanna say it is so helpful to have a platform like this to get advice, I really appreciate it.
     
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    Yetiburger, Oct 8, 2017
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