XJ600n Help (another one!)

[sharpee1984]

Hi all,

Just bought an XJ600 n 2001 weekend just gone and using it for commuting 10 miles per day. When I started her up on Tuesday I noticed a fuel leak, a drip every 2 seconds. On Wednesday on start up and whilst stationary when riding noticed it dripping a bit faster and this morning it was leaking in a constant stream. From my untrained eyes, it looks like it is coming from the fuel pump. I'm not sure if it would be he pump itself or one of the tubes leaking coming from it. How much will this cost to replace/repair? Is it a big job? Is it worth me going back to the guy I bought it from (eBay unfortunately)?

Any help/advice would be greatly appreciated,

Thanks,

Lee
____________________
PRESENT: HONDA CBR600F 2002
Past: Yamaha XJ600N 2001
Past: Hyosung GT125 2008

[Casper]

Fuel pump? did not think they had one. Do you mean the tap at the side of the tank? First change pipe/hoses as they dont last forever. A pic of where you mean if you can.

[sharpee1984]

Its not the fuel/reserve tap on the side, it is leaking on top of the centre of the engine. I cannot take a picture at the moment but after a quick google search it looks like its leaking from the part attached in the photo. As i said, i'm not sure if its one of the pipes or the actual device?
____________________
PRESENT: HONDA CBR600F 2002
Past: Yamaha XJ600N 2001
Past: Hyosung GT125 2008

[stirlinggaz]

that looks like a fuel pump to me.............
i'd start by having a good look at the hoses, they do perish over time so might be worth replacing them before splashing out on a replacement pump,
also have a look at the in-line fuel filter if you have one, i recently traced a leak on my bike to a faulty filter, brand new it was as well! was leaking out the join on the side of filter & because the filter was almost on its side, it would drip out.
took me a while to trace the leak as fuel tends to travel a bit before it drips,lol
cheers,
GAZ

[yandy_yay]

it is a fuel pump and the fuel filter too,

if it's leaking from or very near to where the hoses fit, it worth taking them off (can be a bit tough) and cleaning up the area, fit new hoses if you can, they don't cost much.

i have once seen corrosion bad enough on the fuel pump housing to perforate it allowing fuel to escape that way

oh and the newer 97 onwards ? where fitted with electric pumps the older ones had a vacuum pump.

HTH
____________________
past bikes: (20 years ago) cg-125 (wriiten off), C-50 (thrashed n' finnaly scrapped), CZ-125 (nicked - never recovered, insurance payout was more than i paid for it !!!)
Current bikes: GN 125(now sold), Divvy 600s.

[sharpee1984]

Thanks guys for the responses,

I'll have a closer look tonight/tomorrow morning and see if I can identify where the leak is actually coming from.

As I am not mechanically minded at all, the chances are I'll take it to the nearest garage to sort out! How much should I expect to pay for a fix if it is the pump? Will it be a big job or something that'll only take a couple of hours?

Will I be doing any more serious damage if I ride it home from work tonight and around tomorrow?

Many thanks

Lee
____________________
PRESENT: HONDA CBR600F 2002
Past: Yamaha XJ600N 2001
Past: Hyosung GT125 2008

[Digit]

[yandy_yay]

god don't pay a a garage !!!!

where abouts in the world are you, there may be a BCF spanner god near by

if the worst comes to the worst... ebay for a suitable fuel pump, some pipe, and maybe a new filter, shouldn't cost more that £40

beer/fag tokens for a helpful spannering BCF member jobs a good un.

should only take an hour or so, tank comes off pretty easily (2 bolts) and quickly, followed by the airbox (1 bolt, 4 screws) then you have good access to the area where the pump is.
____________________
past bikes: (20 years ago) cg-125 (wriiten off), C-50 (thrashed n' finnaly scrapped), CZ-125 (nicked - never recovered, insurance payout was more than i paid for it !!!)
Current bikes: GN 125(now sold), Divvy 600s.

[Digit]

Yep!
'The only thing we have to fear is fear it's self!' (FDR.)

Roy.
____________________
Happy daze!

[sharpee1984]

I hate peer pressure

As I have the majority of tomorrow free, I'll get the spanners out and see how far I get! I have just downloaded a copy of he Haynes manual to follow and a quick read through shows it is quite easy to follow.

One quick question, do I need to drain the fuel from the tank before I try and remove it?
____________________
PRESENT: HONDA CBR600F 2002
Past: Yamaha XJ600N 2001
Past: Hyosung GT125 2008

[Digit]

No. And welcome to the world of bike mechanics, we'll have you repairing them for a hobby soon!

Roy.
____________________
Happy daze!

[N cee thirty]

all you need to do is turn the fuel tap off,have some cloth ready and pull the pipes off
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[yandy_yay]

the fuel tap is vacuum operated so as long as it's

1) not faulty.
2) left in main or reserve.
3) NOT IN PRIME !

you shouldn't have to drain it, finding somewhere to balance it so that it's not gonna fall over might be tricky, i ended up with some house bricks and pieces of wood built up suitably high so that the fuel tap wasn't taking the weight of the tank.

this is kinda what you gonna be doing then...

a) remove seat.
b) undo 12mm bolt from behind tank (under the front of the seat)
c) pull vacuum hose (small one) and fuel hose (big one) from the fuel tap
d) remove fuel tap handle (small philips screw)
e) remove bolt from front of tank (10mm i think)
f) lift tank and put to one side

g) remove bolt from front of air box (can't remeber size)
h) undo 4 screws where airbox meets carbs (there a bit like jubilee clips)
i) pull crank case breather hose (near the clutch housing), and camshaft cover hose (get down and look across top of cover from the left side of the bike)
j) lift airbox and put to on side (there is also a longish breather hose that goes between the carbs and down back of engine but isn;t fixed to anything (well usually it's not fixed))
k) remove rubber cover from carbs.

thats it you can now get to the fuel pump/filter easily...

However you should have had a good look (as best as you can) before starting disasembly to see if you can see exactly where the fuel is leaking from.

all of the above is from memory so might not be 100% acurate but it should be close enough. Haynes is ok but sometimes you have to use your common sense too.

Have fun
____________________
past bikes: (20 years ago) cg-125 (wriiten off), C-50 (thrashed n' finnaly scrapped), CZ-125 (nicked - never recovered, insurance payout was more than i paid for it !!!)
Current bikes: GN 125(now sold), Divvy 600s.

[iooi]

While you have the tank off, take a look in the air box. Divvys are well known for filling it with oil from the crankcase breather.
This then should flow down to just behind the rear brake pedal, if the airbox overflow pipe is routed correctly.
You tend to notice this more if bike is left on side stand, as it leans to the side the airbox pipe exits on.
____________________
Just because my bike was A DIVVY, does not mean i am......

[Casper]

So they do have fuel pumps. You learn something new every day. My money is on the pipe still. You will be cheaper paying for me to come down on the train and look at it for you than pay the local bike shop. DIY and good luck, let us know how you get on.

[sharpee1984]

I have now broken my mechanics virginity, it wasn't too painful

I have removed the fuel pump and found the source of the leak. It was coming from the pump itself and not one of the tubes.

Next Job.....find a replacement pump! I have made a few local (Guildford) phone calls but no-one has one in. I can get one ordered from Yamaha but will cost £200+

I am going to give a few motorcycle breakers a call, heard DK Spares is a good source!

I have attached a few pics below of my mammouth project and the dodgy fuel pump

Lee
____________________
PRESENT: HONDA CBR600F 2002
Past: Yamaha XJ600N 2001
Past: Hyosung GT125 2008

[Digit]

[Casper]

Ebay. 50 quid. Look around you might get cheaper

https://cgi.ebay.co.uk/Yamaha-XJ-600-Diversion-Fuel-Pump-%2336_W0QQitemZ110553104264QQcmdZViewItem?rvr_id=134448174093&rvr_id=134448174093&cguid=d467dcc712a0a47a27108730ffcd908f

Sorry i lost the link. there is another for 40 quid on ebay. that is buy now price. Essex if that is close to you.

[yandy_yay]

https://cgi.ebay.co.uk/Yamaha-XV-535-Fuel-Pump-/190440214575?pt=UK_Motorcycle_Parts&hash=item2c571f102f

could quite possibly be made to work
____________________
past bikes: (20 years ago) cg-125 (wriiten off), C-50 (thrashed n' finnaly scrapped), CZ-125 (nicked - never recovered, insurance payout was more than i paid for it !!!)
Current bikes: GN 125(now sold), Divvy 600s.

[sharpee1984]

Well, I received my replacement fuel pump yesterday from Gloucester Bike Specialists LTD, fitted it and had it running perfectly after 1/2 hour! Very impressed with myself, and thanks to all that replied in this thread!

The spare fuel pump came from a 97 Divvy and fitted perfectly. Cost £36 on ebay inc p&p. Bargain concidering I would usually have taken it to a garage to sort out!

Thanks Again,

Lee
____________________
PRESENT: HONDA CBR600F 2002
Past: Yamaha XJ600N 2001
Past: Hyosung GT125 2008

[yandy_yay]

Well done you, most jobs are not too hard as long as you do them in a methodical way, there's usually gonna be someone around thats done whatever it is you need to do no harm in asking if your not sure.
____________________
past bikes: (20 years ago) cg-125 (wriiten off), C-50 (thrashed n' finnaly scrapped), CZ-125 (nicked - never recovered, insurance payout was more than i paid for it !!!)
Current bikes: GN 125(now sold), Divvy 600s.

[Digit]

Yep!

Roy.
____________________
Happy daze!