2016-03-31 KrZy8 Running Rough just above idle

[dcarver]

Crap. The really nice TB assy sold. Got another one, not quite as nice.

 

[RaYzerman19]

Why not just clean your existing injectors, or are they not cleanable? And, put a fuel filter between the aux. tank and the pump......

 

[John d]

I haven't seen anything about you replacing or checking your plug wires. Faulty plug wires will cause misfiring.

Excessive handling of the plug wires can cause the ends to separate slightly. Old wires can also corrode internally at the ends.

Hope that helps.

 

[dcarver]

Why not just clean your existing injectors, or are they not cleanable? And, put a fuel filter between the aux. tank and the pump......

Yes.. will take the injectors to work and use the Ultrasonic bath...

..and fuel filter? Really? Logic?... yes, one purchased and going in-line soonest.

I haven't seen anything about you replacing or checking your plug wires. Faulty plug wires will cause misfiring.
Excessive handling of the plug wires can cause the ends to separate slightly. Old wires can also corrode internally at the ends.

Hope that helps.

Yes.. Gen 2 coils come with integral wires.. All new.

 

[dcarver]

Removed injectors from KrZy8.

JB Weld from ultrasonic tank bottom after cleaning injectors

One injector was really bad. This after the bath and using air to backflush through injector past inlet screen.

After ultrasonic bath. I used a 9 volt battery to actuate the pintel.

Yes, put 4 in a bath, get 5 back. I have 12 injectors and 3 rails in the inventory now..

Don't look, it will poke yer eye out!

Hopefully this weekend will have time to reinstall and test fire KrZy8.

 

[TomInPA]

Oh no, not again!

Let's just put KRAZY8 in the FJR Hall of Fame and go ride Naomi.

 

[dcarver]

But, but, she's trying for 300k miles!

 

[NTXFJR]

Nice! Ever consider doing that for a living?

 

[RossKean]

Nice! Ever consider doing that for a living?

What's that? High end repairs or breaking shit?

 

[dcarver]

Nice! Ever consider doing that for a living?

What's that? High end repairs or breaking shit?

Come on, now Ross. EVERYONE knows I am FAR better at one of those options than the other!

 

[RossKean]

Good going Mr. Carver! Hope that's the only issue. Did you clean the pickup screen of the fuel pump? Bet it has a not-so-thin film of that grey crap all over it. Not to mention the walls of the tank. Pain in the ass, but it wouldn't hurt to (re) start with a pristine fuel system!

 

[dcarver]

Good going Mr. Carver! Hope that's the only issue. Did you clean the pickup screen of the fuel pump? Bet it has a not-so-thin film of that grey crap all over it. Not to mention the walls of the tank. Pain in the ass, but it wouldn't hurt to (re) start with a pristine fuel system!

The aux tank has been thoroughly cleaned when it was rebuilt, baffles removed, and fuel cell foam installed.

The main tank, removed, shaken with 1/8 tank or so several times.

Fuel pp not removed. Too much work for my fat hands to get the pp out. I've done it before, when drilling the bung hole, and it's a PITA.

Filter installed after aux tank, before main tank.

Thinking about installing a filter downstream of pp and before fuel rail. Of course, it would have to handle 39 psig.

Maybe?

 

[dcarver]

Ok then, how to replace clogged injectors. Loosen the the top fuel rail, 3 screws. Don't lose the two spacers on each end, bottom side.

An injector used to live here.

Like this one. To remove the harness plug from the injector, use a set of hemostats to depress the locking tang.

Four hopefully dirty injectors causing the rough running and decel popping.

This is the spacer I alluded to earlier.

This stuff works great on elec connectors.

I bought this tube of syn grease when I was at NERDS in Vermont. It reminds me of good times.

The gas tank is contaminated with JB Weld particulates. The JB Weld patch I used on the aux tank baffle plate broke, the jb weld rubbed against the sharp edge of the lower baffle... very tiny particles.

I mark the housing, even though it's damn near impossible to install it wrong.

Some folks have been able to remove the pump as one unit. I can't figure out how they did it. You can see the tang won't clear the hole.

..to be continued.

 

[RossKean]

Do the injectors have removable (replaceable or cleanable) inlet filter baskets?

 

[dcarver]

Some folks have been able to remove the pump as one unit. I can't figure out how they did it. You can see the tang won't clear the hole.

The way I remove the pump is to remove the level indication assembly from the fuel pp body.
Press the tang, then gently push the assembly downward.

The pump, out of the tank.

Time to flush the tank.

https://www.facebook.com/don.carver.94/videos/10155055459688538/

The floaters are all JB Weld remnants. This is AFTER 2 flushes.

Time to get serious. A little dishs soap goes a loooooong ways.

After 10 or so flushes.. finally looking good.

Time for one last vertical flush.

..to be continued.

 

[dcarver]

Do the injectors have removable (replaceable or cleanable) inlet filter baskets?

I understand they are removable.. but will be damaged so new ones are needed. I was confident my ultrasonic cleaning (with 9 volt battery keeping the pintle open) and back flushing using air cleaned the filters adequately.

 

[RossKean]

Wow. I can't believe that there is that much JB Weld residue after flushing! Are you sure the foam used in the auxiliary tank isn't breaking down?

 

[dcarver]

Here's what was coming out of the tank. This is not dish soap..

Time for a blow job.. to dry the tank..

https://www.facebook.com/don.carver.94/videos/10155055460133538/

No comments from the peanut gallery...

Close up views of the fuel pump. I wonder how gallons this puppy has pumped over 200k miles?

Level indicator assembly

The big test.. Will she start? Will she run OK? If not, I don't know what else to do..

https://www.facebook.com/don.carver.94/videos/10155055460668538/

200k + miles.. Still looking and running good!

Many thanks to FjRay who convinced me to do the job correctly the first time.. in other words, to remove the fuel pump in order to thoroughly clean the tank. I had talked myself out of it - too much work. After seeing the severity of contamination, I'm glad I did.

Rode KrZy8 to work this morning. About 55 miles. She runs GREAT! MPG went from 23 - 25 to 38 - 41. WooHoo!

 

[dcarver]

Wow. I can't believe that there is that much JB Weld residue after flushing! Are you sure the foam used in the auxiliary tank isn't breaking down?

Positive. I knew the JB Weld had broken free and that the baffle plate was vibrating. I just never thought that the JB Weld be ground down from the vibration and rubbing. I had earlier taken KrZy8 into the shop when I failed to troubleshoot the problem. I replaced CPU, 1 injector, TPS, barometric press sensor.. New plugs, coils-wire-cap too.

What 'fixed' it was swapping the entire FI assembly with a new to me from ebay. Then, after ~5,000 miles.. the issue reared its ugly head again.

I found the problem by accident. I had removed the aux tank cap to polish the aluminum. The sun was shining with a perfect angle illuminating the gas. Hey, wait, why does the gas have a tinge of gray? Looking at the JB Weld, what used to be ~3/8" 'buildup' had been reduced to less than 1'8". All that material is what is seen here.

 

[Brodie]

Nice when things work out well.

Good job Don !

Kind of reminds me of what our friend in Florida went through a few years back with his contaminated tank. I believe his was from contaminated gas.

Every so often before pumping gas, I shine my maglight down the fill port to see how well the fuel filter pillow is doing. Was your filter getting plugged? Did you do anything to clean it?

Brodie