Triumphrat

trucku

Here is how I cleaned out my TT600s tank and internals after the fuel has been sitting in it for a LONG time.

here are the pictures (many)

All cleaning to small parts were done with a Ultrasonic Cleaner with heat option. I bought it from Harbor freight for about $80. The Ultrasonic Cleaner has a option to heat the liquid inside to about 150degrees Fahrenheit.
IMO its a great machine to have. It is a excellent way to clean little parts without touching them with a brush and harsh chemicals. It works very well. I cleaned my Mass airflow sensor and 6 injectors for my truck with it. I could not have done a better job manually.



This is the fuel pump assembly BEFORE! The tank has been remove and the fuel pump assembly removed from inside.
Brace yourself.



This is the fuel pump assembly AFTER! Hours later and numerous Ultrasonic baths (disassembled for cleaning)



The fuel pump was totally frozen. I would not spin with 9v or 12v. I just kept on giving it Ultrasonic cycles. I finally pulled off the pre filter and was able to see into pump. I could see the impeller. I tried to move it but it did not move. I thought the pump was dead. I ran it through many many more cycles of 140+ degree soapy water. Eventually it turned when I pushed on the impeller. It was obvious the pump was extremely gummed up. After 2 hours in the Ultrasonic cleaner I was able to energize with the 9v batter and have it kick over 45degrees. Finally after more cleaning cycles I use 12v and had the pump running in the Ultrasonic Bath. It was a beautiful sight and relief from thinking I needed a new pump.



This is one of 4 injectors that was cleaned. They were very dirty with rusty residue on them. They also did not make much if any noise when I energized them (9v) battery.




Here is the first one cleaned. I did 6 cycles of 8minute Ultrasonic baths. I also pulsed injector while in the bath to allow it to be cleaned thoroughly.



The tank was a nightmare to clean inside. In the end I zip tied a sponge with the green pad to a long old wooden spoon and just reached in and scrubbed away. This was after many man attempts to rinse out the inside with very hot water. It took about 2 hours before I had it clean. I dried the inside of the tank with lots of paper towels.


Organizing pictures. Will add them after upload of them are complete

Here is the all the pictures I took. They may be out of order, but it gives you at look at the cleaning process.

GNTurbo6

Wow that's a lot of rust. You may want to try using some POR-15 to kill the rust and rust proof everything.

__________________
'00 TT600
'87 GN

sailfish

Sorry, but I have to ask. How did things get that way?

trucku

Unfortunately my bike has been sitting a LONG time. As long as my 4 year old is, so I was no too surprised. The garage I had it in was very leaky and humit. Bike only has 1700 miles on it so it was more than a shame.


Thanks for the Por-15, I didn't know about it. I was looking for something to coat the inside of the tank. I won't let this type of neglect happen again.

trucku

Wife had a baby, then the riding risk became something apparent. My wife didn't want me to ride. The bike was 3 miles from me in a damp leaky garage. Time just went by. I started it as often as possible, but then finally the fuel pump gave up.

This was my attempt to redeem myself and bring this bike back to life.

BombFactory

Thanks for the post! It is good to have such details on the fuel pump for those who have never seen the system before. That was some nasty rust/grime; I hope the pump holds out, as that would be disappointing if it doesn't after all the work. I'm assuming you will be doing a full cleaning or replacing of the other fuel system components (i.e. fuel rail, hoses, fittings, etc.)?

So what is the history of the bike? That gas must have been in there for a while along with some water it looks like.

[Edit]: Looks like you beat me to the history of the bike!

__________________
The Resurrection: ’02 CE Speedtona w/GSXR Forks
The Reviving: Speed-TT Project
"When I reflect upon the number of disagreeable people who I know have gone to a better world, I am moved to lead a different life." - Pudd'nhead Wilson

trucku

I bought it new in 2000 and it only has 1700 miles on it. Yes the **** garage always had every **** thing wet.

I will clean everything else leading into the into top end. I think the pump is fine. The minute it failed I turned of my ignition. There was no time for it to burn out.

I think one of my fork tubes is leaking. I saw some oil on it. I am hoping the seal didn't fail but just bled out a bit form lack of use.

The fuel was a nice color of rust and has a weird sweetish smell to it.

Honestly taking it apart was very easy. I took pictures of all the connections beforehand. I even marked each injector connection from 1-4 so I know the order. I did the same with the injectors just to make sure they go back where they came from.

The tank has 3 bolts that hold it down. Then you disconnect all the breathers and unclip the feed fuel and then return fuel fittings. You just have to pull on the clip and they pop right off. The fuel rail disconnects with 2 torx screws. The injectors come right out along with the harness. I disconnected the harness then pulled the injectors.

trucku

Update. The fuel pump is working fine. I tested the pump with ignition on and fuel fitting out. I used a screwdriver to depress internal valve and the pump primed up and pushed out lots of fuel. Unfortunately I was never able to find a fuel filter, SOOO... I used the original filter. I back flushed it. No issues with original filter. The only thing new put into my tank pump assembly was new hoses (originals all but disintegrated)

Still Not Start.
After over 5 years (closer to 6) of sitting I was still having trouble starting the bike.
I pulled the plugs and this is what they looked like this



The 2 oxidized were from cylinders 1 and 4.

I broke out the ultrasonic cleaner and started each on 3 cleaning cycles of 8 minutes with heated water.
I also used wired brushed the spark plugs before the last cleaning cycle.

The plug on the right is before wire brush and final clean. The left plug is done.


I checked the gap on the plugs and for a bike with only 1774 miles on it they were from .6mm to .8mm. I gaped the cr9ek to .7mm (both outer electrodes)

Before it is asked, I saw no need to replace these plugs. They were in good shape and just needed a cleaning.
I installed the plugs and coils.

I still had trouble starting the bike, but noticed when the pump primed it didn't sound like it was pushing fuel the the rail. Turns out the valves on the male fitting and female tank fitting didn't seem to be pushing on each other to open (fitting installed). I put a small stainless steel spring in the male fitting. This allowed it when installed to push on the valve on the tank female fitting. Worked like a charm and I could hear the pump prime up a bit longer as it pressurized the fuel rail.

Good news the bike started up like a charm. Everything ran beautifully. I let idle for 30 minutes to make sure nothing failed (thermostat, electric fan).

Now I just have to give her a test ride. I am going to follow advice from a member and try to clean out a seal that may be leaking on the left fork tube.

GNTurbo6

If you have the tank off again could you take a pic of this? My bike never starts easily but once its warm it runs great. Maybe it's because of something similar.

__________________
'00 TT600
'87 GN

trucku

My bike would always have issues starting after sitting a couple of days. I used to open and close the gas cap to get her to start
Your fitting under the tank for the fuel pump out (RED) and return (White) are quick release. You just push on the metal clip and the male fitting can be pulled right out. The fitting on the left side of the rail goes to the red female connector and the right side of the rail to the white connector. You can loosen the tank and then tilt it on its side, but propping it up with something on the air box. I used a small jar to hold tank up. I used a big towel to put between the tank and frame to keep her from getting all scratched up. I then disconnected the red connector. I used a flat head screwdriver to test to see if pump was working. push into the female connector and depress the valve. DON'T force it. Its all plastic. You will break it. Take it easy and it will give. Once in just energize the pump and it should push out fuel for a couple of seconds. If it flows freely then your filter isn't clogged.

I will say that my plugs were all gaped differently for some reason. I bought this bike new and never changed anything. So re-gapping IMHO helped. I made all the gaps to the center electrode .7mm on each spark plug. It starts right up now nicely. I will let her sit a couple of days and see if I have any starting issues and post it here.