Coolant leak and sludge at bottom of engine

You’re getting there. Drum roll please! Did the fuel petcock on one of mine last year. Kept getting a fuel odor from a tiny leak.

Sounds like you’re just testing for leaks and pump operation. Acceleration / carb performance will likely be off with EXUP not operating.

Isleoman said:

You’re getting there. Drum roll please! Did the fuel petcock on one of mine last year. Kept getting a fuel odor from a tiny leak.

Sounds like you’re just testing for leaks and pump operation. Acceleration / carb performance will likely be off with EXUP not operating.

Click to expand...

Thanks! Looks like the EXUP has not operated for a long while, the valve is totally seized - even the application of heat, philosophy and extreme violence has not freed it off!
I decided that I can take a look at that once the rest is done!

I got it all back together on Saturday and started to fill the cooling system....



Bu@@er! The 'O' ring on the pipe at the end of the pump was not seated properly and had been damaged as I tightened the pipe on, so have ordered a new one - just glad it was an external pipe that is the issue!

I took the pipe off to prepare for the new one arriving, you can see the pump through the hole - anyone got a knack for putting this pipe on? I put the 'O' Ring on the pipe before inserting it, but it went over the flange, should I seat it in the hole in the crank case first before putting the pipe in. I must admit this pipe is probably the worst to fit!

The bike is still fighting me every step of the effing way!!!!
took 5 attempts to get that 'O' ring seated properly so it doesn't leak only to then find that the little pipe on the water pump at the front has a split in it!
Part no 35 in this diagram:


So, I am just trying to find a second-hand one as it looks like they are only available from Japan.... Hmmpphhh!!!!
Will I ever get to ride this bike again?

The only good news is that she started on first press and is running really, really nicely.... which makes it even worse!

This is why I fear this issue. I followed a FZ!oa member’s thread on this and he ended up doing it multiple times. That’s a fairly cheap new part in the US.

You’re close to being done.

Managed to find a second hand pipe, fitted it and all seems good! Took 3 attempts to leave my village as each time my oil light came on so went home and put another dash in. Even though I put the required 2.7Litres in, I think having changed the filter and pump meant that it needed a bit more....

Then I fitted the Fairing and did a 90 mile ride and all the fluids stayed where they should be, so I'll take that as a win!

Good news. The general rule of thumb at the old FZ1oa was that filling Gen 1s to just below the top of site glass prevents oil light from coming on.

Based on the work you’ve been doing it’s prudent to check all possibilities.