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91 GSX600-F Project

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  • #1

    91 GSX600-F Project

    Apparently the PO did a motor swap from a 96 or 97.

    Current problems (in order of importance imo):
    1. gas/oil in the airbox and gas in the oil.
    2. Idle is inconsistant. It hangs and dies when warm.
    3. Exhaust is burning Blue (I suspect its due to the risen oil level from gas)
    4. Turn signals turn on but don't blink.
    5. Bar end hits the tank on the right side. (rides fine)
    6. Plastic is beat to hell
    7. fuel guage doesnt work.


    Let me preface by saying I have little to no mechanical experience previous to this. What little knowledge I have, I've picked up from here over the course of the last couple months. I'm posting in this section because I'll be posting pictures of every little thing I do for yout review (I don't want to blow her up).

    Plan of attack:
    From what I've read here, dirty carbs and/or a stuck float are likely causing the first 3 issues.
    I'm going to start tearing it down tonight.
    1. clean carbs
    2. rinse tank
    3. change fuel filters
    4. new air filter (& clean air box)
    5. change the oil
    Hopefully that clears up 1 - 3.

    I'd like some recommendaions for 4 - 7. I haven't researched those issues since they haven't really effected my riding. I've been using hand signals for turning. pictures and a quick video showing how it ran coming soon.
    Hetland
    91 GSX600F
    Tags: None
  • #2
    4. If both lights on each side light up solid but don't blink, you need to replace your flasher. Go to napa, pick up the $2 one, and wire it in.

    5. your right bar is bent most likely, but the steering stop could be broke... My bet is on bent bar.

    6. Check out the section of the website all about paint and fairing repair.

    7. Check the wires are plugged in first. From the tank bottom to the middle of the wiring harnes right about next to the battery. Wire colors will match, bullet end connectors.


    The other stuff sounds about right.


    Krey
    93 750 Kat



    Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

    "I've done this a thousand times before. What could possibly go wron.... Ooops!"

    Comment

    • #3
      Thanks Kreylyn, the electical was hooked up for the gauge, but not the hose off the unit on the tank (its been missing as long as I've had it) where should the hose go when I replace it? My repair manual doesnt specify.
      Hetland
      91 GSX600F

      Comment

      • #4
        [ame="http://www.youtube.com/watch?v=aZwXINzc5NE"]http://www.youtube.com/watch?v=aZwXINzc5NE[/ame]

        This is what it was running like before I started tearing it down. I think the rattle is the passenger foot pegs.
        Last edited by Hetland; 05-10-2011, 10:42 PM.
        Hetland
        91 GSX600F

        Comment

        • #5
          Not sure what I'm doing with the pictures, but here it goes
          Attached Files
          Hetland
          91 GSX600F

          Comment

          • #6
            Some Goo around the airbox boots. Any idea what it is, and after I clean it all up is there something I should use to help keep it sealed?
            Attached Files
            Hetland
            91 GSX600F

            Comment

            • #7
              Originally posted by Hetland View Post
              Some Goo around the airbox boots. Any idea what it is, and after I clean it all up is there something I should use to help keep it sealed?
              Probably to keep the boots tightly sealed to the airbox so there aren't any leaks. I replaced all my boots but didn't put any sealant on it, seems to be fine though as the new rubber is supple enough to make a good seal.

              Comment

              • #8
                quick question on the air boots. they're a little egg shaped. I've read a few posts that recommend boiling them to get them to return to their original shape. Is it a good idea, and is there a recommended way to let them cool?
                Hetland
                91 GSX600F

                Comment

                • #9
                  Originally posted by Hetland View Post
                  quick question on the air boots. they're a little egg shaped. I've read a few posts that recommend boiling them to get them to return to their original shape. Is it a good idea, and is there a recommended way to let them cool?

                  The carb bodies are oval (egg shaped) so it's not a problem.

                  Use a gasket sealer (fuel resistant) on the boots when you put them back on the airbox.

                  If you do boil them, nothing special... boil for 5 mins, let air dry/cool.

                  Krey
                  93 750 Kat



                  Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

                  "I've done this a thousand times before. What could possibly go wron.... Ooops!"

                  Comment

                  • #10
                    What kind of problem can missing or damaged vacume chamber o rings cause? was missing 2 and 1 was practically chalk.
                    Hetland
                    91 GSX600F

                    Comment

                    • #11
                      alright, ran into a bit of a hickup. I'm suppose to "Remove the needle jet from the top of the carburetor." How does it come out? should it drop out? do I pry it out? I've tried pushing it out with a hard piece of plastic, and I tried briefly to pry it from the top, but it's pretty much flush with the inside of the carburator. I figured I'd better ask before I damaged something.
                      Hetland
                      91 GSX600F

                      Comment

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