Yesterday, Zyvek asked why it wouldn't be a good idea to modify a stock VFR fuel pressure regulator yourself: http://www.vfrdiscussion.com/forum/index.p...ic=16229&hl=diy
So today I had the bike apart for its 16,000 mile service. I flushed the cooling system, brakes and clutch, changed the oil and filter (MB1 15W-40 gold cap), got rid of the PAIR system
(as per: http://www.vfrdiscussion.com/forum/index.p...hl=pair+system),
checked valve clearances (all perfect at 16,068 miles), checked synch on the starter valves (similar in principle to this VTEC thread:
http://www.vfrdiscussion.com/forum/index.php?showtopic=7935),
and cleaned and oiled the K&N.
So I figured, "What the hell, I'm in this far, why not try to modify my own fuel pressure regulator (FPR)? I can always get a new one for $39 if I screw up."
So I removed the velocity stacks and airbox pan (lots of hoses and coil wires - take pictures or have a shop manual handy unless you have a photographic memory), clamped the fuel return hose (on bottom of FPR - big fuel spill if you don't clamp it!) and used it to drain the tank into a gas can; removed tank and side fairings (I had other work to do, so it all had to go), pulled off the vacuum hose to the FPR, and cracked it loose from the fuel rail.
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Intake Plumbing and FPR
Here's where I ran into a headache, and I can't advise you to do what I did (I've since had a better idea. See below). The fuel return nipple on the FPR spins around and hits the choke adjuster-screw stop plate, so instead of removing the fuel rail I just grabbed a socket and very gently bent the nipple until the FPR came free. (IMG:http://www.vfrdiscussion.com/forum/style_emoticons/default/goofy.gif)
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Bending the Fuel Return Nipple
Once I had it out, I took it to the vise and gave it a gentle tap. I was surprised how little force was required. One tap pushed the FPR spring seat inward about 2mm, so I called it good at that.
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Highly Scientific Modification
Installing the FPR required that I re-straighten the fuel return nipple, and you better believe I was scared I'd crack or break it, but this cheesy metal bends nicely so mine was okay.
The better idea? Leaving the tank attached, remove the airbox and plug open vacuum lines. Without removing the FPR, grab a paint stir stick, hold a ball bearing (approx 3/8"-1/2". From a hobby shop??) on an extension magnet and position it between the frame and the spring seat recess on the FPR. Using the stir stick to protect the frame, insert a pry bar between the ball bearing and stir stick and gently pry the seat inward about 2 mm.
Better idea yet? Start the engine with a fuel pressure gauge attached, get a baseline reading, then pry the spring seat in and watch the fuel pressure until you have it just right. Wish I'd thought of it before I did what I did (IMG:http://www.vfrdiscussion.com/forum/style_emoticons/default/dry.gif) .
I went ahead and buttoned everything up and put a "T" in my fuel feed line permanently for easy fuel pressure readings later. I now have 40.5 psi fuel pressure (up from 36 psi stock. Shoot for about a 3.6-5 psi increase with this mod, or approx 10% over stock pressure), and the bike starts and runs beautifully.
Tomorrow I'll put the fairings back on, burp the cooling system again, check fluids and go for a ride. I have the aforementioned K&N air filter and a Satantune, so I've likely been running lean with only my ecm running the fuel delivery show. With this mod I expect to see a slight (hopefully noticeable!) increase in power (especially just off idle) without significant loss of fuel economy. I'll post results.
Need sleeeeeeeep now (IMG:http://www.vfrdiscussion.com/forum/style_emoticons/default/blink.gif)