Poor Running - Poorly Gen 1 - Diagnostic and repair

[crash_matt]

Update - Daylight working

Had another go at the Busa today, this time in daylight hours. Took the fuel rail off and managed to get it all back and leak free this time.
Injectors on #3 &#4 swapped over to see if I could make the fault move.

Answer = nope.

The problem went away! Took it for a 30 mile run to see if I could get it to go again, as before after running it up warm and doing some shorter test runs then leaving it a good number of hours as it loles to creep back in. No issues, just blistering acceleration as you would expect of the bike. Too early to be confident, but....

 

[sixpack577]

It's back....

So, fewling full of myself and eager to go for a proper journey I fired up the Busa again, just a matter of a few hours after the 'fix'. All set to fill up and enjoy and damn it, the bloody thing is lumpy again.

No change when it warmed up either, so back to the garage. Tank up and checking and sure enough #3 is the culprit again. So...

Pull the coil packs and switch for a neighbour. - no change.
Put different plug into coil and check for spark against frame - all good.
Pull the plug from #3 and repeat - good spark. So..

Thinking that this is pretty much deffo the injector I check voltage in loom when running. All good.
Check that there is still a circuit in the injector. All good.
Figure right, let's swap #3 for #4 and make the problem move to be confident that it's the injector, not the cylinder. Problem....

Got them out, 3 goes into 4 no bother, but will injector 4 go into the fuel rail at position 3? Nope. Not for love nor money. Curious I think let's pull it from the fuel rail and look. Eventually it goes in, but plastic port on the rail looks slightly worn wonky. (Take the opportunity to blow it through again to clear any crut).

Next issue, can't get the fuel rail to go into the side of the damn plastic section of #3! Check the o-ring, add oil to help, nope... change the o ring (for one in a halfords box) no better, find another, think I've got it in, but no, fuel passing out of the gap! Try again, still no dice.

So late night 'genius idea' turns out to be a bloody daft one. There was a constant drip, even with the bike switched off. I'm guessing just gravity pushing through the pump as the tank is now full and vertical. Back to clamps on the hoses and waiting for my next brainwave or parts delivery, which ever daft solution comes along next!!

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On another note, thanks for the awesome tips on injectors. Does anyone have a pic of the filter coming out of one of these buggers?

Glad you got it running well again, hopefully it continues.

As for the injector filters, they are aftermarket only, as Suzuki considers them part of the injector.
To replace them, you need to thread in a machine screw of similiar size(I forget what size works(M3 or M4).
The threads just chew into the oem filter itself, to grip it to pull it out, and a vice can really help, as some filters can be difficult to pull out.
Once out, I then flush the injectors both directions(spray cleaner), and activate them with a battery when doing so.
Then, put the new filter on a flat surface and Gently push the injector down on it.
I have also yet to find any generic o-rings to fit any injectors, as most are odd or part specific sizes...hence your previous leak when you tried them.
These are pictures of the last injector filters/screens that I replaced, and are from my Gsxr1000.
The injector filters usually disintegrate before they clog too
These injectors look different from the Busa's, but the assembly and function are the same, the parts just are not interchangable between the two.