[Woody357]

Id been hot after this 2002 919 (6k miles) for a couple years since I sold a similar one to fund a race bike build for my son. When I heard about this one in the back of a literal barn, I started BEGGING to buy it. The owner is an older friend of mine who works at the local bike shop. He’s sort of a hoarder of motorcycles as he has NEVER sold a single machine since the late 70s. He’s got some really cool bikes in his barn including old race quads/ATCs and MX bikes. This week he finally decided to sell one to me. His 919 (his wife has a red one back there too)
Things I Know;
It was stored with fuel and stabilizer in the tank, but the fuel pump is shot. Has power going to the pump but it’s not even attempting to kick on.
Tires were new when it was parked and that’s a shame because they are likely also shot from sitting. I’d need new tires anyway because I’m about 5 miles from the nearest paved road and typical “sport” tires are unruly in our and that’s just the very beginning of my 90 mile commute to work (and the end of my 90 mile trip home).
Right now I’m on a Vulcan 900 Classic making that commute and while it’s been a trusty steed; I really do not enjoy cruisers (or V-Twins). My Magna is about the only cruiser I care for and really only because it’s got a hopped up V4 and is a MEAN bike. So I sold the Vulcan to the shop for $1000 profit and now it’s a scramble to get the 919 on the road. I only bought the Vulcan because it was in killer shape for a killer deal and I hoped it would be a better option for a LONG commute over the Magna and I wasn’t about to kick my 72 CL350 down the interstate at 2am.
So that’s it’s for now I guess. Have a little bit of work ahead of me but I am hoping no more than a weekends worth.

pictures are of the mentioned Vulcan, my old 919, and this one.

 

[marylandmike]

Congrats Woody. That looks like a great find and she cleaned up nice!

 

[Islandboy]

Very cool. The 2002 is the best year in my opinion. Best colour too. Such low mileage and stock too. I’m green with envy. Change fluids, tyres and your good to go. Maybe wash that barn dust off too.

 

[bikerep]

Very nice find you got there Woody! Welcome to the community!

 

[Woody357]

Ok, so the bike is home and new fuel pump came…

tank is pretty rusty inside. Mostly just surface rust and I can get my hand inside with a scrubber and get a lot of it off. So just going to flush that tank until I’m satisfied.
I need a fuel filter and a gasket too and didn’t order those like a dummy.
Tires are HOSED. Awful. So that’s gonna set me back a while before I can ride it. Promised my wife no more projects so imagine her surprise when she walks in the shop and sees the 919 without a tank or a seat.

tires: looking at a 90/10 style tire (my commute involves a bit of dirt road travel).

Tank: I’ve used vinegar in the past. Anyone have tips? It’s crusty surface rust. I’m gonna flush it a bunch and plan on replacing the pickup screen and fuel filter at least two more times.

Fork seals are cracked. I guess that’s not really a surprise. Just a note.

Packrat made a nest in the air filter but didn’t actually chew the element. That was kind of him. Lots of mud daubers too.


had some electrical gremlins the first night. Starter wouldn’t kick on when I hit the button. Lights dimmed but that was it. I messed with it a bit and eventually it came on. I haven’t been able to replicate the issue, but maybe it rings a bell to someone? Maybe something to keep an eye on or check if it happens again?

anyway just kind of tinkering away while I wait on more parts. Paid $2400 was hoping to keep it below $3000 total investment (tires not included). Had a mantis show up and hang out with me for a little bit. I consider them a good luck creature and I’d be glad to have any positive energy at this point.

 

[Woody357]

Also: it is a 2003 with 8881 on the clock. I’m happy under 10k on these motors.

 

[K1w1Boy]

had some electrical gremlins the first night. Starter wouldn’t kick on when I hit the button. Lights dimmed but that was it. I messed with it a bit and eventually it came on. I haven’t been able to replicate the issue, but maybe it rings a bell to someone? Maybe something to keep an eye on or check if it happens again?

The starter button is notorious for "drying out" in some way, so that contact becomes intermittent - I'd look at the handlebar end of things first.

 

[Islandboy]

Damn shame the tank/ fuel pump got rusty. And dry rot in the rubber. My bike was in a similar condition when I picked it up. Stored/neglected for ten years.
I’ve used toilet bowl cleaner on rusty fuel tanks with great success before. I blocked off holes with plugs carved from polystyrene. Google it.

 

[Woody357]

Wheels are off and headed to the shop for new rubber and bearings. I went with the Bridgestone Battlax AX41S tires. I needed something geared a little more towards an adventure tire

while that all goes down I’m still waiting on the rest of the parts to repair the sending unit. Plugs, Air Filter, Block off Plates, and the brackets for the F series windscreen are on the way. So far I blew my intended investment by about $350. Most of that was the tires as I had a set lined up (Dunlop) for $200 but decided I needed something for aggressive for my dirt roads between my house and the highway.

the tank has been coming along nicely. I am able to get my hand inside the tank with a short bristle brush and PB blaster and have scrubbed a substantial amount of rust out of it. I let it “dry” and flakes migrate to the bottom where I can vacuum them out. It’s kind of a long process but I have time right now so it’s fine. I also took the switches apart and cleaned them up. Everything seems to work a lot better now and the buttons aren’t sticking.

 

[Baldy]

Sounds like could be a bad starter relay. Easy to replace. It's under your seat. I normally use evaporust on tanks. You can find it at all the big hardware stores. Would recommend new fuel pressure relief valve and cleaning injectors since it sat with bad gas. Good luck with your project.

 

[cav45]

To clean out the tank you could drop some nuts and bolts in there with solvent, and shake it. Or even a chain with small links. That gets the job done.

 

[Woody357]

She’s all back together. Definitely not the most grueling Or stressful revival but it definitely has has me pretty anxious. Coming into fall and nearing the end of riding season I really wanted to get it out on the road a few times.

Replaced everything in the sending unit.
New plugs and oil/filter change.
New tires and Wheel Bearings.
Pair Valve deleted.
New wind deflection and grips.
Fresh oil and filter.
New chain.

Did some other things here and there while waiting on parts off and on over the last couple of weeks. Just filled the tank with fuel and checked for leaks at the sending unit gasket. So far so good. All that is left is to crank it over and see if she runs. 10 years in a barn has come down to this moment. But first; Dinner. Because if I am going to be pissed off when it doesn’t fire up at least I won’t be hungry too….no one needs that around here.
So stand by and I’ll be back.

 

[Woody357]

919 cranked right over and fired up. Let it idle about 5 minutes and only issue it seems so far is some coolant coming from the overflow. Hoping it’s just an overfilled system doing it job and not something worse.

 

[Islandboy]

Woo-hoo! Glad to hear the bike started.
Mine has let a little coolant go whenever I’ve drained and put coolant into the system. Probably just a result of working out some trapped air. I don’t think a little puddle is anything to worry about on the first startup.

 

[Woody357]

So I have determined that the coolant system is just way over full. When I pull the reservoir cap it is right at the cap. Good there. temp gauge is funny. Starts way below the parameters of the gauge and after a short ride moves about 1/2-3/4 of an inch but still below “normal” operating temp. Think that’s a sensor issue or maybe a gauge calibration issue.

however, during my short ride I noticed a severe lack of power. It idles very inconsistently and has no throttle response below 3.5k RPMs. I did manage to get the bike to 70mph and get through the gears but anything below 4K RPMs and it is hesitant and even after 4K is doesn’t respond well to throttle. Almost like it’s dead on a cylinder or not receiving enough fuel when demanded. I don’t know. Was hoping to ride to work tomorrow but now we are going to pull the tank off and trouble shoot spark. Then I guess I need to look at fuel pump relay? Maybe it’s working intermittently? Or pressure sensor? Any ideas or where to look next?

anyway. Draining fuel from the tank now.After work I’ll pull the tank and check my spark hoping the easiest will be the issue. After that I don’t know at this point. Took the wind from my sails pretty good today.

 

[Islandboy]

On first starting up the bike check to see if the headers are heating evenly.
Could be a failed FPR.
Make sure your tank is venting.
Could be a gummed up injector.

 

[Woody357]

On first starting up the bike check to see if the headers are heating evenly.
Could be a failed FPR.
Make sure your tank is venting.
Could be a gummed up injector.

regulator, or injector are my targets right now. I didn’t think to check header temps when I pulled it into the shop. I was a bit defeated. I pulled the tank, going to verify spark on all 4 plugs first.

 

[Ultra54]

Huh.... "Barn Find", shouldn't it be "Bike Find"? Who gives a fuck about the barn, it's about the bike!

 

[mynameisthomas]

had same issue with low performance and the problem is that 1 of the 4 cyl not firing- replaced the splugs with new ones and that solved the issue

nvm found your new thread updates

 

[Woody357]

Alright folks. Been a while since I’ve done much with the 919. It’s running right with new tires, bearings, and chain.

with the new and cleaned fuel system it started falling on its face. Come to find out there was a loose hose at the pump that was spraying fuel into the tank instead of into the system. So basically it was running on gravity instead of fuel pressure. I guess anyway, because it ran. Like crap albeit, but running.
That is fixed and now I am just waiting on some warmer morning to start riding it in search for the next batch of bugs to work out.

the decals were all cracked and faded from sitting. So I removed them and replaced them. Was going to do a red ”accent” theme (hence the new decals) but decided against it after some of them were on so I removed them, added black accent tank decals and going to run black decals on the body.

Turn signals bodies on the aftermarket blinkers were crap and the body pulled away from the mounts. Not wanting to buy anything else before being able to ride I found a set of small (but bright) LED signals in the barn from another projects I had going. So I think I’ll use those for now.
I also have a rear rack on the way because I need a little cargo capacity for my longer commutes and overnight work trips. Not sure how it’s gonna look on the 919 but y’all will be the second ones to know 😅

for now just waiting on the weather to break 45 overnight. Low 30s at 3am is just a bit out of my comfort zone for a trip to work. I’m hoping the hand guards and windscreen help….but not pressing my luck sub 40 degrees.
✌🏼Woody