'93-'95 900RRs had fuel pumps, appears that '96+ went with a gravity feed. I've decided to go to as close as stock as possible to begin with.

I have the fuel leak sorted, need to look into the choke circuits on the carbs as it doesn't like to start with the choke.

 

I’ve just done the carbs on mine, top tip don’t use aftermarket float valves, I used tourmax and they don’t seal, I rang NRP and Allen’s performance carb specialists, they both said do not use aftermarket float valves, they don’t use them because they always leak, I ended up refitting the originals.

have you checked the pilot screw settings, could be it’s too rich and doesn’t like choke because of that?

 

I found the right size jets to go back to stock, plan to put those in tonight and see if there's any difference. Pilot screws are 2 turns out, should be fine there.

Yanked the carbs from the original engine and found all sorts of lovely...

 

Pretty gruesome!

 

“Try Oxicllean for all your tough rust problems!!”

 

I may or may not clean those carbs, not sure yet. I decided to tear down/clean the good set of carbs I have, fixed the fuel leak at the same time. Stock air box, K&N filter, stock jets, bike does not like to start with choke, but idles just fine once it's started. Now, time to check into the next issue, as there is a not-so-lovely rattle coming from the right side of the engine, and there are metal shavings in the oil. My gut tells me it's a rod knock, but I'm hoping to get lucky and find a worn-out cam chain guide, something simple please.

 

Movie won’t play on my iPhone, good luck with it being an easy fix 👍

 

I'll look into converting the video format and reposting it. I took the timing cover off and it's perfectly clean inside, taking that as a good sign. Also, the engine doesn't rattle when it's first started up, only once some heat starts getting into it. I need to adjust the valves anyways, time to tear into the top end and see what I find.

 

Now I'll need some help from the resident gurus... I've taken the valve cover off to adjust the valves, but with the aftermarket timing advancer on it, there are no timing marks. I have an OEM ignition pulse rotor from an F2 and it bolts right up. Does anybody know if the timing can be sent using the F2 rotor? Does anyone have a 900/919 pulse rotor to compare to the F2 rotor in the pick below? Also, it appears that something has been rubbing/grinding on the engine casing between the timing chain, might have been from failed OEM cam chain tensioner?


Aftermarket timing rotor/advancer

OEM F2 timing rotor

 

Got it sorted - F2 and 900RR have same part number for timing rotor. Now I need to order timing chain and guides, then can complete valve adjustment.