Project Linkin's FZR250R 3LN3

OK. This bike has the wrong CDI unit for the engine anyway... Cobbled together piece of ... that is better now it's had the Dr. Murdo and fizzer factory special touch.

Tomorrow I will change out the water for coolant, swap radiator fans (and inspect the failed one), reset the carb idle mixtures & main idle, and test ride... Then go for a test ride... AFTER that, if all is well, put the remaining plastic bits back on.

Can't stretch funds for new tyres at the moment, so I reckon I'll wear out the current ones and put new ones on later.

 

Changed out the tap water for proper Nulon Red coolant today. Changed out radiator fan without having to drain the system (had already filled up with coolant - d'oh!). The nut that holds the fan on had come loose.

Put a little more Delo 400 in the bike as a precaution more than anything... level was below the sight glass.

Decided against putting new exhaust gaskets on, only because it's a pain to get the headers in the right spot so everything lines, on my own.

Fuel tap... I put the original non-viton o-ring back in. It is a little thicker than the viton one. However this did not stop the leak. The tap is definitely seated all the way in. @Grasshopper 's bike has all the viton bits in it, and it stopped his leak. Should have left mine alone as it was fine. I think the screws are the culprit. Only 2 of them and the heads are soft, can't torque them very much. I think some new allen head or torx ones are a good idea.

I also put the ram-air tubes on, then went for a ride.

Words cannot describe how tight the bike feels. Compression feels great, engine pulls from low revs, no flat spots. Oh and the gearbox is heaven compared to @Grasshopper 's. Tight and smooth, not clunky at all... which is a Yamaha gearbox trait! That Delo 400 Multigrade is the bee's knees! The ONLY thing wrong with the bike now is having fat tyres on... might be fine for the racetrack, but not for the street.

 

Also fiddled with the idle circuit. It will idle and start properly, but still hangs a bit before dropping to idle.

 

Only difference now compared to before we dismantled the bike is that it's got new airbox boots. I believe the actual standard setting for the idle circuit is 3 turns out. 2 and 1/4 turns and it was almost impossible to start the bike. 2 and a half was hard to start and needed throttle or choke. 2 and 3/4 turns and you can start it without throttle... Will try 3 turns out tomorrow.

 

That makes it a lot clearer Blair. The black o-ring that came out looks to be the 1.89mm one. The Viton one I put in was OR-048. Appears that I need OR-049, which is what we put in Grasshopper's bike to fix his leak (his fuel tap plate screws are lunch meat as well)

As for the round thing with holes under the o-ring that sits in the tap. The 3LN6, Grasshopper's 3LN3, and this 3LN3/7 all have FT-004 and OR-049 or OEM equivalents in them.

OR-048 and FT-003 must belong to a different fuel tap. Grey's 3LN1 has a different fuel tap compared to all the other fizzers, but we haven't opened it to have a look.

 

Part numbers to the rescue!

2GH-24500-00 is the OEM part for the older fizzers. Superceded by 3LN-24500-00.

http://bit.ly/1RTnwqt

CMS image appears to be the same as what Grey has on his bike, but it's not clear if the image is the same as what you get if you order one.

My head is spinning... but I THINK this is the situation

Grey's bike has the newer fuel tap 3LN-24500-00 which looks like this



The rest of the bikes have 2GH-24500-00 which looks like



This explains the supposed "wrong" seals etc. The fuel taps on the bikes are mixed up! I can only wonder why the newer bikes have old fuel taps, and why Grey's "older" 3LN1 has a newer fuel tap.

 

I reckon you'll need to update your website photos with photos of each tap and which seals the different types need