FZR400 1WG Genesis bad idle,float height, emulsion

[fstarocka]

Hi guys -

having a NIGHTMARE getting my buddies fzr to get going..

Ive METICULOUSLY cleaned the carbs twice.. plugs were fouling and I cleaned em up so now not too bad..

I am stumped about correct float height? At first I was caught between the later models that use a 23mm height - not possible in these carbs.. no room imo - so im sure im with the 13mm versions..

Manual states to have a float level 4.5mm-7.5mm below the two lines cast in the carb (using the drain hole and clear tube method)..

So i eventually got mine close.. at 13mm the bike almost sounded better.. I had to drop float level to around 11mm to get it closer to the spec..

Anyway - now the bike is still struggling to idle well - it keeps hunting, the dying, and idling rough.. at mid / higher rpms the bike sounds VERY smooth - revs climb smooth without hesitation..

So ive done TONS of reading - and about to conclude the emulsion tubes are worn - ALL the symptoms ive read point to these things wearing and dumping droplets of fuel into motor at idle / low rpms -

This from the manual:



Mine before adjusting float some more:



Vid of the bad idling - excuse sound qual isnt studio

[youtube]https://www.youtube.com/watch?v=NHZ_XCo ... e=youtu.be[/youtube]

Mine after adjustment:


https://www.youtube.com/watch?v=NHZ_XCo ... e=youtu.be

Feel free to give me any tips / info etc - will be pulling carbs for the 1000th time to try remove the emulsion tubes and snap some more pics.. Ill be writing a darn sticky after this bloody lot!!

Another user posted part numbers for this bike (see 1WG)

"
Be careful here guys. If I recall correctly, the 3EN2 400 carbs are more similar to the 3HE 600 carbs than those found on the 1WG 400 (which is what you would get by ordering from Factory Pro). I did a little cross-checking and found the following part numbers for needle jets for these three bikes:

3EN2 400 ---- 3EN-14141-92
1WG 400 ---- 3BF-1490J-00 (mine)
3HE 600 ---- 3EN-14141-90

"

[Evilchicken0]

I thought yours was a Genesis rather than 3BF.

Have a look at the needles, if the emulsion tubes have been ovaled the needles will usually have a shiney mark on them where they rub.
Have you balanced the carbs - I'd guess you have as you've done everything else.
You say the plugs foul, is it running rich at all, it could be the air jets need adjusting to tweek the idle mixture.

Lastly - the thing I usually say is - take it to a Dyno if you can one run will give you a good idea of whats happening.

[laminator]

As EC mentioned, have you balanced your carbs?

Checked for air leaks on the inlets?

If it's running rough below 4000 rpm but fine over that, is it your pilot jets blocked?

good luck.

[fstarocka]

Well engine block says 1wg - and i thought the genesis is the 86/87 level?

anyway - i did plug in my home made vac gauge and syncd em - still having issues.. one mix screw is screwed up.. totally mangled.. i assumed it was at the right place cos they tried drilling it out very badly and unsuccessfully..

prob look for a new set of carbs.. these things need more work than I have time to spend weeks getting nowhere..

[willandrip]

Hi, I think the info you are using is as near as you can get for a Genesis. There is no specific manual for it unless you read Japanese.

As you have found.......all the pre 3TJ models have 1WG stamped on the casing....with no numbers.

I think , if anything ,you need to replicate the angle that the carbs are when fixed to an upright level motorcycle
when using the fuel level gauge.

If you think the emulsion tubes are worn to excess then fit a drill shank as near to the dia. as possible into the tube
and view against daylight. The shank helps to highlight any ovality.

[Evilchicken0]

Even the 3tj engine has 1wg on the cases.
You could get an infrared thermometer and take the temperature of each downpipe that might give an indication which cylinder is rough. Really thought another set of carbs would be best

[willandrip]

Boris.....do the 3TJ models have engine numbers ?

On the carbs....often the ones for sale are in a worse state than the ones being replaced.

[Evilchicken0]

nope no numbers on the 3tj motors

Will, could he use 3en carbs, the cylinder spacing is the same but would they fit into the rubbers ? (I know the Genesis uses metal manifolds with seals whereas the 3en is one vulcanised rubber piece ???

[willandrip]

I do not know if the carbs would fit Boris.

I was fortunate with all my 400s in that none had need to swap out the carbs....except one 3EN2 which I replaced with 3HE carbs and swapped all the jets.

They all use the same airbox AFAIK .....the jetting could be mix/match.

Now,I have not been in the garage for a long time...but I seem to recall that one bank of carbs had the remains of a
damaged mixture screw with no head stuck in place.
I slotted the outer recess that it is in with a dremmel...cutting a new slot into what remained of the mixture screw.

Having a vast supply of different screwdrivers aids immensely with soft brass screws.

[Evilchicken0]

Drill with a left hand bit, drill in reverse gear - might be enough to unscrew it