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Another Leak......


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#1 gozer

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Posted 19 May 2020 - 04:59 pm

So I finally got round to sorting the split coolant pipe on the mk1 that comes out of the rocker cover today. Job done, I think. As I was running it up to temp to make sure, fuel started gushing out of the overflow. Because it`s been a long while in storage, I thought it might just be a sticky float so gave the float bows a few taps but it`s still chucking it out. In an effort to see which carb it was, I disconnected the fuel line from the fuel pump and hung the aux tank up high to gravity feed the carbs as I didn`t fancy petrol pissing out right next to/onto a roasting hot exhaust. No fuel from overflows, so thinking that the tapping of the bowls had done the trick I put it all back together and fired it up again. Yep, you guessed it, pouring out again.

So my Q`s are, wouldn`t directly feeding the carbs by gravity simulate the problem, or am I being a numpty? and is there any possibility that the pump is over supplying?

I suppose I`ll be left with no option than to remove the carbs to clean and check the float needles, so is there anything that I should be aware of when the float bowls come off?

Also a quick electrical question. Unless the front brake lever is pushed right out the brake light either flickers or stays on.  Is there any way of adjusting the disc that operates the front brake light switch in the master cylinder of is this to do with a weak spring and i'll need to rebuild the master cylinder? 

All help/suggestions/piss taking gratefully received...



#2 Studley Ramrod

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Posted 19 May 2020 - 05:42 pm

According to the Haynes book of fairytales, the front brake switch isn't adjustable.  Is the switch secured nice and tight ?  Just wondering if it's worked loose.


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#3 gozer

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Posted 19 May 2020 - 05:54 pm

Yes, all nice and tight, that was the first thing I checked as I`ve been caught out with that one before.



#4 Andy25

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Posted 19 May 2020 - 06:14 pm

're Brake switch
Had a similar experience with my mk2 bought a replacement switch
But the fitment was slightly different so had to open both up and swap the inside's
The little spring like contacts had worn out on the original

Simple enough just fiddly

Just had a quick look @ Wemoto £13.09 in stock

Edited by Andy25, 19 May 2020 - 06:21 pm.


#5 butcher650

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Posted 20 May 2020 - 09:16 am

My brake light switch in the past had had it's little arm bent at the top, so it faced towards the plunger a bit more, and I straightened it out. Turned out it was the wiring causing it not to work properly. Since I've fixed the wiring, its working a treat. One of the wires from the loom into the back of the plug was loose.

As for your fuel issue, I should imagine if you give the carbs a good clean, new gaskets, and a sync, they'll be ok again. Perhaps the little fuel filter in the feed to the carbs from the pump has got some crap in it?

#6 gozer

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Posted 21 May 2020 - 11:59 am

So I got the carbs off yesterday afternoon. Looks like some ham fisted gibbon had been in there before and the float bowl screws were soooo `kin tight. I managed to get 6 of them undone but on 2 of them the slots actually gave up the ghost and rounded off. Not a slipping driver, I was using a tight fitting JIS driver, it was the actual metal that gave way! Looks like a couple of hours of mind numbing fun with the dremel carefully grinding the heads off then. What a  jolly wheeze!!!



#7 Studley Ramrod

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Posted 21 May 2020 - 02:46 pm

Jolly weeze indeed. Happens quite often Gozer.  Usually if the bowls haven't been off for years.  Screws are toffie like.  Hope it all goes well for you. :good:


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#8 Catteeclan

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Posted 21 May 2020 - 03:48 pm

I've got a tiny pair of mole grips for jobs like that, work very well.


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#9 drewpy

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Posted 21 May 2020 - 05:07 pm

So I got the carbs off yesterday afternoon. Looks like some ham fisted gibbon had been in there before and the float bowl screws were soooo `kin tight. I managed to get 6 of them undone but on 2 of them the slots actually gave up the ghost and rounded off. Not a slipping driver, I was using a tight fitting JIS driver, it was the actual metal that gave way! Looks like a couple of hours of mind numbing fun with the dremel carefully grinding the heads off then. What a  jolly wheeze!!!

i drilled one of mine, even saved the thread


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#10 Studley Ramrod

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Posted 21 May 2020 - 06:20 pm

I've tried that, and failed big time. :lol:


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#11 gozer

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Posted 26 May 2020 - 10:47 am

Waited until I`d calmed down a bit after the screwheads  made of cheese lark and then had another go. Before I went at them all gung-ho and ground the heads off completely, I got the smallest tungsten bit I`ve got in the dremel and ground  coarse slots in the two knackered ones. I put the fattest flat bit I`ve got in the impact driver and used it as a screwdriver. They were still bloody tight but, TA DA! Success, they came out, threads intact. Fiddling time now to see if I can find out why they suddenly started overflowing.



#12 gozer

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Posted 01 June 2020 - 01:10 pm

Took the float bowls off and pulled the floats and float needle housings and everything looks pristine. Not even any discolouration in there. I`ve checked the needle tips and seats with high magnification, they look perfect, and all o rings appear to be in good condition and I can`t find anything amiss. I`m now waiting for new gaskets / o rings and needles as I might as well change them while I`ve got the chance. It does bring me back to the question in my opening post though, is there any chance the pump can over deliver fuel ? Just seems bloody strange that the prob  started so suddenly. Also, is it possible to set the fuel level with the carbs off the bike??

Ta



#13 dablik

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Posted 01 June 2020 - 03:38 pm

Mine were also pristine and still leaked till i took em off and cleaned again, fuel levels off the bike, put on a flush surface with a little bolster under the back edge, a 10mm thick piece of timber did for me and levels on the bike fine...it's to mimic the position of the carbs when in-situ..


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#14 gozer

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Posted 07 June 2020 - 05:01 pm

Got the gaskets etc and come to put the carbs back together. I thought I`d got some m5 panhead screws to replace the two mullered ones but the heads are too big, they bind up on the side of the float bowl before they are fully home, so I`ll have to order some.

If poss, could someone confirm that the size is m5 x 0.8 12mm?

TIA



#15 gozer

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Posted 19 June 2020 - 11:02 am

After some closer inspection, it turned out that the overflowing on the carbs was due to the o rings on the needle seat bodies. I guess they must have dried out after being sat for so long. All seems good now. As I had to butcher a couple of the float bowl screws to get them out I needed a couple but although they are only 60p each from fowlers the postage was a fiver!! If like me you like to use the correct stuff, I found these guys on ebay. Good prices for small quantities delivered quickly and saves having to use generic stuff that`s not quite right and they sell them in older pitch sizes too, so good for anybody working on older bikes.

 

https://www.ebay.co....=p2047675.l2562



#16 steve27bha

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Posted 19 June 2020 - 01:17 pm

Got the gaskets etc and come to put the carbs back together. I thought I`d got some m5 panhead screws to replace the two mullered ones but the heads are too big, they bind up on the side of the float bowl before they are fully home, so I`ll have to order some.

...

I missed this earlier.

Howzabout socket head screws? Better for getting them out again too.

M5 x 0.8 DIN socket head diameter 8.5mm  https://www.engineer..._head_screw.htm

M5 x 0.8 DIN pan head diameter 10.0mm  https://monsterbolts...ant=36469458380


Edited by steve27bha, 19 June 2020 - 01:19 pm.

TDM900A 2008/09 in use, with     gallery_179098_391_770.jpg sml_gallery_179098_391_1145.jpg  gallery_179098_391_1206.jpg gallery_179098_391_253.jpg gallery_179098_391_82.jpg gallery_179098_391_725.gif gallery_179098_391_797.jpg gallery_179098_391_1396.jpg gallery_179098_391_501.jpg gallery_179098_391_316.jpg  gallery_179098_391_1768.jpg gallery_179098_391_106.jpggallery_179098_391_2170.jpg gallery_179098_391_1373.jpg

 

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#17 gozer

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Posted 19 June 2020 - 01:30 pm

I missed this earlier.

Howzabout socket head screws? Better for getting them out again too.

M5 x 0.8 DIN socket head diameter 8.5mm  https://www.engineer..._head_screw.htm

M5 x 0.8 DIN pan head diameter 10.0mm  https://monsterbolts...ant=36469458380

 

Thanks Steve but all sorted now. Do you have commercial interests in the USA?? both those sites are America based, so prob a long, and expensive journey! :unsure2:

I bought the correct screws just down the road in Bromsgrove!



#18 Studley Ramrod

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Posted 19 June 2020 - 05:45 pm

After some closer inspection, it turned out that the overflowing on the carbs was due to the o rings on the needle seat bodies. I guess they must have dried out after being sat for so long. All seems good now. As I had to butcher a couple of the float bowl screws to get them out I needed a couple but although they are only 60p each from fowlers the postage was a fiver!! If like me you like to use the correct stuff, I found these guys on ebay. Good prices for small quantities delivered quickly and saves having to use generic stuff that`s not quite right and they sell them in older pitch sizes too, so good for anybody working on older bikes.

 

https://www.ebay.co....=p2047675.l2562

Good find. :good: Might invest in some of their self tappers.


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#19 steve27bha

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Posted 19 June 2020 - 08:15 pm

 

...both those sites are America based, so prob a long, and expensive journey! :unsure2:

...

The sites are there purely as reference to justify what I said. My former job expected statements to be supported by evidence!  (no, not a copper!)

They came from a Googlle search.

 

I had used socket heads to do the rebuild of a set of carbs on a Z400J after struggling to remove the originals, many years ago now.

 

Your story led me to check on my local stainless supplier, to find he has retired, so no more popping round for the odd item and a blether, unfortunately. Thank you, CCS.
 


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#20 MipeTDM

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Posted 21 June 2020 - 08:30 am

If you can get hold of some Torx socket heads, they're much better even than normal Hex bolts. Less chance of stripping one out.




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