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2002 Honda CBR 600 F4i Leaking Fuel Regulator...common??

5489 Views 11 Replies 8 Participants Last post by  bc-lefty
Hey guys and gals, a question for all of you me chanically savvy individuals out there. I have had the bike for over a month now, just in the last few days in the morning I have noticed a small amount of fuel dripping onto the garage floor when the bike is cold. As the day goes on and everything warms up there is little to no fuel leak so it really hasnt bothered me all that much..... until tonight.

I decided to see what the heck was going on, pull the bike apart to frame and tank and take a peek at whats going on. I traced the leak to the regulator (small anodized canister that is attached to the fuel rail), I watch it drip and shut the bike off and get to work. After many improvised tools to get at the lower bolt I finally have it nailed and get the FPR out. I notice a small nick on the o-ring, so lucky me I happen to have a replacement o ring, replace it and put everything together again and it still leaks, no change, a drip a second.

As I watch this happen I notice that the leaks are coming from the crimped edge of the regulator, so I remove the regulator once again and grab my pliers and squeeze the crimp down tight, reinstall and start it up, the leak has slowed considerably 1 drip every 2 seconds now but still not stopped, however I kno I am on the right track. Remove it once again and this time use a pair of vise grips set to crimp at the same pressure all the way around this time, as well I used some fuel safe anaerobic sealer to run around the edge of the crimp . I have reinstalled it and put the bike together again, I have not started it yet as I am waiting for the sealer to dry. This i just a temporary fix just to get me through a bike ride tomorrow and then I will be looking to order a new one n Monday.

However my questions are, is this a common problem? has anyone else run into this issue? As well are replacement FPR hard to come by or expensive? Again this is on a 2002 CBR F4i.

I could do a write up on the removal and installation process if there is any interest as I now have it down to about 3 minutes to remove it and 3 mins. to reinstall.
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ive got the same bike and no problems whatsoever yet to speak of
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