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Discussion Starter #1
Firstly I apologise for starting a new thread on this but I have done a search of this forum and have found so many different answers to this problem I thought I would post my particular circumstances and see what help I can get.

I bought my 05 600RR a few months back. Seems to be in perfect condition. I bought it at 9500kms with a BMC filter, Yoshi slip on and Power Commander III. The previous owner said that its last service was done (at a bike shop) at 7500kms. I rode the bike about 600kms to get it home and it ran beautifully but I didn't give it much use after that due to the weather.

Last weekend I filled it up with BP Ultimate (98) and rode about 100-150kms away from home no sweat. About half way back I was giving it a good hard run and it started surging, enough to drop 2-3km/hr of the speedo instantly and jolt a bit. It progressively got worse until I could not get the bike over 60km/hr and it was spitting something fierce and decided to pull up. Had a bit of a break and gave it another go and it took off fine for a while but slowly crept in again. The tank was empty when I got home so I filled up at a different servo and put some injector cleaner/octane boost in it.

I got the bike home and have only ridden it to and from work since, and it does not give me any grief at all on these short rides. Just took it for a steady ride about 25kms away and half was back it starting surging again (not as bad though but I was taking it easy).

I am fairly mechanically savvy with cars but bikes are fairly new to me. There is so many different threads on this issue so I was wondering if I could get an idea of where to start on this problem. If anyone could give me some ideas of what to check sort of from the most common problem to the obscure and if you know of any links to a work log please post those too because I'm not real familiar with the bike. (Thanks for reading my long a$$ story).
 

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Is there a vacuum building up in the tank? If so you want to check your vent line.
 

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Discussion Starter #3
Is there a vacuum building up in the tank? If so you want to check your vent line.
And of all the things I might have half an idea about, that I have never even heard of. So to answer your question I have no idea if there is a vacuum in the tank.

Could you elaborate on the cause of this and where the vent line would be? (I'm a complete noob at this)
 

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Vent line runs from under the tank and comes out just next to the front sprocket / water pump.

The top of the tank is sealed so that you don't get water ingress which creates a problem when the bike pumps all of the fuel out - causes a vacuum... as the vacuum increases the pump finds it harder and harder to supply enough fuel and it ends up starving the engine at high rpm (and hence high fuel demand).

The vent line is there to prevent this from happening by allowing air back into the tank from somewhere it isn't to likely to have water work its way into the tank, such as below the level of the tank through a small pipe...

To find out, ride around for a while, shut the bike down and open the fuel cap, if its difficult to open then you have a vacuum building up in there...
 

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Discussion Starter #5
Cheers man. I half remember it being hard to open the tank when I got back into town to refuel but can't say I was taking that much notice. Thought the key might have been getting a bit stiff to turn and not fully disengaging the lock rather than a vacuum pulling from underneath.

I'll see if I can't blow some air through the vent pipe and let you know if there was any pronblems.
 

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Discussion Starter #6
Vent line runs from under the tank and comes out just next to the front sprocket / water pump.

The top of the tank is sealed so that you don't get water ingress which creates a problem when the bike pumps all of the fuel out - causes a vacuum... as the vacuum increases the pump finds it harder and harder to supply enough fuel and it ends up starving the engine at high rpm (and hence high fuel demand).

The vent line is there to prevent this from happening by allowing air back into the tank from somewhere it isn't to likely to have water work its way into the tank, such as below the level of the tank through a small pipe...

To find out, ride around for a while, shut the bike down and open the fuel cap, if its difficult to open then you have a vacuum building up in there...
What a mission!!!! Seemed like a lot of effort to get under the tank with all the fairings and what not. Anyway, I've disconnected the breather hose and can blow air through it just fine in both directions. I've blown through the end connected to the tank and the pressure builds up, then it blows back out when I let go. Seems to be fine and no clogs. Opened the filler cap and can blow through the tank end fine as well. Does not seem obstructed in any way.

I have a bad feeling this is my problem though - http://www.600rr.net/vb/showthread.php?t=226684&highlight=how+to+remove+fuel+tank+2005+05

I stuck a torch in the tank to try and see the inside of the tank where the breather comes in and looks like there is a lot of crap in there. Just slimy and scaly **** over the tubes and stuff in there. And the tank near the filler hole all gritty and wipes off in a rust colour. Certainly doesn't look as bad as the rust in that thread but enough to make me 'WTF'!!!

Next step looks like taking the fuel pump out and checking out the insides of the tank. Scratching my head though as to why or how you would get rust inside the tank, hopefully I can prevent it happening again if thats what it is!
 

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Could be that.

And its easy enough to get water in there if your not careful, and if you have been using ethanol fuel the ethanol itself will absorb water...

BTW, do you drink rum?
 

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Discussion Starter #8
Could be that.

And its easy enough to get water in there if your not careful, and if you have been using ethanol fuel the ethanol itself will absorb water...

BTW, do you drink rum?
I live near the factory man, we have more rum here than we know what to do with lol. I do security there sometimes when they launch new products and the bogans live outside the factory for weeks to be the first to get the new flavour.

Nope, never used Ethanol, the manual advised against it. Always use 98 octane from BP. The rust makes sense, because the previous owner said he never rode it, and it was bone dry when I purchased it.

I think I am a bit rubbish at using the search engine, everything I search for just brings up the same 12309u423094203 threads. Can you point me in the direction of some instructions to drain the tank, get the tank off, and get the fuel pump out??
 

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Best suggestion for that would be the service manual mate.

Its not hard though... just siphon the tank as much as possible then take off the seat, ram air covers, fuel tank cover to get at the fuel tank itself, then undo its bolts, pull it up from the front, pull off the breathers, then with a rag under it undo the banjo bolt holding the fuel line.

After that there is just a few screws holding the pump in.
 

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Discussion Starter #10
Best suggestion for that would be the service manual mate.

Its not hard though... just siphon the tank as much as possible then take off the seat, ram air covers, fuel tank cover to get at the fuel tank itself, then undo its bolts, pull it up from the front, pull off the breathers, then with a rag under it undo the banjo bolt holding the fuel line.

After that there is just a few screws holding the pump in.
Just put it all back together so it can take me to work tomorrow. But it looked like the tank itself was only suspended by the two bolts which it pivots up on.

And I thought there might have been more of a trick to getting the fuel out than just undoing the line under the pump and hoping it doesn't spill. But I'm on the second last bar of fuel so should be good to go very soon.

Just need to get some of this - http://www.kbs-coatings.com.au/KBS-MotorCycle-Tank-Sealer-Kit_p_13.html
 

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It will spill, that's why you siphon as much out as you can and use a rag under the line when you undo it...

There shouldn't be to much come out though cause when you lift the tank it will get all the fuel away from the line...

There are four bolts holding it on, two up the front and two up the back.
 

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Discussion Starter #12
Looks like it shouldn't be too much of a hassle. Well now that I know how to get the tank cover off.

Has me worried about the car now too, its been sitting around going no where for years since I've been riding bikes.
 

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Discussion Starter #13
It will spill, that's why you siphon as much out as you can and use a rag under the line when you undo it...

There shouldn't be to much come out though cause when you lift the tank it will get all the fuel away from the line...

There are four bolts holding it on, two up the front and two up the back.
Is there any trick with the power wires or anything else? Forgot to have a close look at those...just a male/female connection that pops straight off I'm hoping.
 

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Discussion Starter #15
Few false starts on getting the siphon going but the tank is now empty. Got my KBS tank kit on hand and am ready to rock and roll. Not too much crap in the fuel siphoned out. We'll see how it is when I get the pump off. Taking a few photos for a work log along the way.
 

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Discussion Starter #16
Definately a rust issue. The bottom of the fuel pump is fairly well clogged. Luckily it doesn't look too flakey and just grainy. The inside of the tank just looks like surface rust and not even that bad.

Do we think I can save the pump?? Any suggestions on how to clean it?? Chemicals to use etc?

I'll put in the first step of the tank saver while I await replies :)
 

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Discussion Starter #17
The tank sealer kit was much much more difficult to use than I first thought. Getting a water tight seal without using the OEM seals is a tough job.

In the meantime I cleaned the pump with some Inox (WD40 stuff). Turned out ok. There is next to no rust flakes/pieces in the orange gauze so I am quite hopeful.
 

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Discussion Starter #18
Got Part 1 and 2 of the tank cleaner kit done. Some before and after pics. This stuff does an amazing job.

Bit of surface rust has found its way inside while it is drying out, but Part 3 says this won't effect the seal. So far so good.......
 

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