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Looks like this forums's domain changed. I edited the image links with the new 600riders.com domain to fix the images.

Well, turns out the dealer tech troubleshooting was correct: defective fuel pump. A new fuel pump has it running flawlessly. It's a stunning $800 repair (pump+troubleshooting+install). I'm headed to the dealer now to pick up the FZ6 and ride it home. I was really hoping the tech was wrong...

The dealer tech used a separate test pump and fuel supply, and the bike "ran flawlessly." There's no need to check pump pressure when you have a known-good pump on the bench. I don't know if the tech used the bike power supply or not, so there's a slim chance the issue is power. That's why...

The dealer service manager just called me. The pump is defective. That sucks. As everyone here knows, a new pump assembly is $600. I'm having the dealer install a new pump. Fazil: I'm not mad at you. There's no way you could have known the pump wasn't working properly.

No good news. All troubleshooting indicates the fuel pump you sold me is defective. It isn't maintaining 35psi. I'm throwing in the towel and taking the FZ6 to my local Yamaha dealer for troubleshooting. That way if the dealer tell me the pump assembly is defective, and I buy a new $600...

The fuel rail is solid except for the pop-off valve, and 4 injector holes. There is no Schrader valve or nipple on the fuel rail. I'd have to put one inline with the fuel line. Not thrilled with that idea. The pump bench tested with 12VDC and it buzzed. I didn't bench pressure test the...

What's more likely: all 4 injectors simultaneously losing power after start-up or the used fuel pump not maintaining 35 PSI?

San Jose. Fully reassembled. Purchased pump from Fazil, a member of this forum. Supposedly a known-good pump. The injector harness is fine. All 4 exhaust headers get hot when I spray starter fluid into the airbox. This bike has been garage stored its' entire life. All fuses and fuse...

The auto parts store fuel pressure gauge kit is $60. The local Yamaha dealer is 0.5 mile away and wants $95 to diagnose the issue. I have a wife ans=d 8mo son. This is taking too much time. The CA rollover valve is on the return line which connects to a hard pipe to the TOP of the tank just...

The engine runs for a few seconds on its own fuel every time I cycle the ignition key. It runs great with starter fuel sprayed into the throttle bodies. Once I stop spraying, the engine quits. The kill switch is okay. Looking at buying a fuel pressure gauge kit and put that question to rest.

Okay, I got some free time to troubleshoot the 2004 FZ6. After the fuel injector and rail cleaning (they didn't need cleaning - they were perfectly clean), same problem as my March 22 post: Bike starts, runs for a few seconds and stalls. With key ON and kill switch ON, the fuel pump primes...

I didn't get any rust or debris in the fuel injector back flush. The forward flush with water and 30psi air shows good spray pattern from all 4 holes on each injector. The #1 injector didn't flow well at all with just air. After a water flush, all are very good. The injector rail is...

Got the tight screws off using a trick for removing damaged carb float bowl screws: use vice grips on the screw head, while also twisting with a screwdriver. The fuel rail was completely clean. Zero signs of rust. All 4 injectors open with an audible click with 12VDC applied. Zero signs...

Haven't had a free weekend to remove and clean the injectors. :( Tank is off. Air box is off. Fuel rail and air balance phillips screws are soft brass and torqued by a gorilla. Patience required.

I took a page from the Super Tenere non-start troubleshooting. The recommendation is hold the throttle wide open, hold the starter for 20 seconds, and let go of the throttle. The FZ6 fired right up. (Yes, the starter should not be run for more than a few seconds at a time to prevent...

Thanks for the flush details. I will start with assuming the fuel rail is filled with vapor, not liquid fuel and see if I can keep it running enough for the rail to fill. (That begs the question of the factory and dealers process to get new bikes running. There should be a bleed screw, but it...

Thanks for the spec. My 50psi was just a guess. I haven't checked the fuel rail and don't have a pressure gauge for it. All four exhast headers get hot, so I think all injectors are clear. Could they all be partially fouled? Maybe. Haven't considered how to troubleshoot them. The supply...

Confirmed. The unit was very clean, and the pump passed a 12VDC bench test and it also primes on the bike. The bike ran when parked and the only failure was the pump unit. The unit is probably good, but I have to troubleshoot it regardless.

No. The reverse electrolysis removes red rust without acid. It takes longer, but the final result doesn't require a sealer or coating. I have zero confidence in a sealer or coating lasting long term, meaning decades. I have restored two 30 year old bikes and have talked to the owners...

I have completed the reverse electrolysis and updated the first page with pics. The fuel pump arrived from Turkey. It passed a power test and I mounted it in the tank with the fuel level sensor, also bench tested with an ohm meter. Haven't filled the tank with fuel yet. Ran out of spare time.