Just found out... Just got off the phone with the mechanic today. It seems that the fan to cool the engine was running right from the get go, as soon as you start the bike. He's now put in some part that senses the temperature and only turns on when needed. Also, the fuel pump he used was from a car!!!!! and this coupled with the fun somehow stopped enough charge getting to the battery. Now, i wasn't paying that much attention to the conversation as i didn't understand most of it, but that seems to be the gist of it. The fuel leak wasn't actually a leak, but overflow, which isn't happening after a series of test rides. FINGERS CROSSED! I'm picking it up tomorrow, and the fix was totally free. Thanks again for the ideas relating to the front brake light guys. ACE, do you mind if i get a bit more information on the screw and alteration made on your front brake in regards to the light. Cheers.
Wiring the radiator fan on is a common mod for people who can’t be jigged replacing the thermostat or have air trapped in the cooling system but don’t know it.
The plunger that is released when you pull the lever releases a sprung bit of brass ,i think it is brass and that makes the connection on the spade. The bit that makes the contact with the spade on mine had worn into the plastic so I bent the bit of brass a little bit and scraped the little nick back in the plastic, it is very fidely when you get inside. I just got an on off switch for my fan. I think it is working but I want the option.
Update Ok, after 4 days at the mechanics, my little fzr is now running extremely well. This is what it took: *Full carby clean *New radiator cap *New seals *temp gauge cut out for fan *other stuff i can't remember/understand There are now no leaks anywhere, no issues with battery, and the thing just loves to scream. Awesome. Two resulting issues though, it gets hot real quick now, but cools down quickly too (must be the fan kicking in). Also, it is pretty weak down low, sometimes feels totally unresponsive in 1st gear, in the first 5 mins of riding (not sure if running a bit rich or just needs to warm up??). Anyway, still happy for a total of $1500, great cheap bike! Thanks again for everyone's help. Damien.
My bike is fairly sedate and unresponsive when below the little marker on the temp gauge. I always take time to warm the bike up and go easy on it until the needle gets past what I assume is the operating temperature marker.