The Ray - 2001 R6 Rebuild Log - Page 2 - Yamaha R6 Forum: YZF-R6 Forums
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post #11 of 63 (permalink) Old 04-11-2019, 09:47 PM
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Re: The Ray - 2001 R6 Rebuild Log

Quote:
Originally Posted by ctag View Post
I dunno man. It's like visiting the wise man on the mountain, some things are only apparent after enough engagement with the topic at hand.

We'll get you sorted though. Do you have a bike? How's the weather over there?
I do bro I got an 5EB just like you, doing a similiar rebuild, will be posting a thread soon. Stay tuned!
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post #12 of 63 (permalink) Old 04-28-2019, 01:10 PM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Gaskets are in, trying to reassemble the carbs.

I'm unnerved that I can't see down the emulsion tube.. But apparently it's normal?


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post #13 of 63 (permalink) Old 05-06-2019, 06:33 AM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Finished rebuilding the carbs!

Replaced the spark plugs, just for good measure.

Then I lost the key for a few days, finally found it hiding on a keychain I'd looked at a dozen times...

While hooking the carbs back up I noticed that the coolant to the carbs has been bypassed, and most of the EGR / emissions vacuum pieces are gone.

OK, carbs are back on the bike, and it runs! Kinda..

I took it down the street and back when I first got it, and there wasn't a problem. But after reinstalling the carbs the bike will start, and then immediately die when I put it in gear. I tracked the issue down to the Starting Circuit Cutoff Relay box, and after finding that they're $100 to replace, I cut this one open. It looks like some of the diodes went bad. They should be easy enough to replace; does anyone know where I can find similar ones to swap in?

** edit: I also noticed that the voltage rectifier has been replaced.. That likely has something to do with the fried diodes, right?

When I measure between the "Sky Blue" and "Blue/Yellow" or "Sky Blue" and "Black/Yellow" wires I get either no connection (against the diode) or something around 11 MOhms (with the diode). Pretty sure they're shot.


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Last edited by ctag; 05-06-2019 at 06:37 AM.
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post #14 of 63 (permalink) Old 05-19-2019, 06:13 AM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Found a faulty diode (D8) on the relay board and replaced it with a 1N4007. That fixed it!

While trying to start the bike though, I noticed gas had filled the crankcase... So the carbs are leaking, which sucks because turning off the petcock on the tank is a huge pain.

Now that I'm back on track, I still need to figure out what the next steps are for tuning and getting the carbs and engine back to 100%

Also, I noticed that the new brake reservoir line was sweating the oil out.... Does anyone have a suggestion on what I should get to replace it?
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post #15 of 63 (permalink) Old 05-21-2019, 02:25 PM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Bought some parts

- Front brake reservoir and line
- Front righthand brake caliper, line, rotor, and bolts
- Fork rebuild kit
- Bar end mirror

While that's all shipping I need to get back out there and pull the carbs one last time to find which one is leaking and then fix it.

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post #16 of 63 (permalink) Old 05-21-2019, 06:34 PM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Took the bike out for a spin just now. At around 35 mph the engine starts fluttering and faltering. Possibly a fuel delivery issue?

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post #17 of 63 (permalink) Old 06-09-2019, 07:16 PM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

I wrote this whole post and it didn't submit :-/

OK. I've had the carbs off for a while as I tried to fix the gas leak. Carb #1 still leaks, even after I replaced the float valve with a new one. It sucks, for now I'm just turning off the petcock.

Today I rebuilt the front forks with new bearings, seals, and oil. I don't know how to adjust them. Will have to look into that. I accidentally left the top washer out of the left hand one, and I don't know how to get just the oil seal back out to install it without another full teardown.

While putting the front end back together I discovered that the previous owner had installed the wheel backwards! With that fixed the left hand brake caliper "just fits" without needed those random washers offsetting it. I'm now waiting on a double banjo bolt before I can install the new right hand caliper.
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post #18 of 63 (permalink) Old 06-10-2019, 08:50 PM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Took the bike back out today. Again, at about half throttle the engine just bogs down and threatens to quit.

I'm going to borrow a friend's sync gauge set and try to check if the carbs are in sync.

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post #19 of 63 (permalink) Old 06-12-2019, 06:38 AM Thread Starter
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Re: The Ray - 2001 R6 Rebuild Log

Bought new vacuum line for the gauges, but was informed to do a valve clearance check first, and only after that sync the carbs.

I got the valve cover off and it looks like the intake valve are all in spec (0.1mm gauge fits) but the exhaust valves are not (0.2mm gauge sticks). I'm not sure how to tell if the gauge is feeling resistance because of the clearance between the valve and cam, or because the gauge has to bend past the edge of the engine in order to get in there..
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post #20 of 63 (permalink) Old 06-12-2019, 07:49 AM
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Re: The Ray - 2001 R6 Rebuild Log

Good work so far, that R6 is finally getting the love it deserves.


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