I had a few hours free on Saturday afternoon. During the week my ebay purchases had arrived, a tank, front brake master cylinder and a head light. I offered the headlight up to the shell and was happy to find it would fit once I had tidied up the wiring in the shell. I set the tank to one side. It look fine when a collected it on Wednesday evening. I stripped the master cylinder of the braided lines and the hand lever cable. In the process I dropped the spacer pin and could not find it. I knew it could not get far. I took the wire brush to the metal body and gave it a good scrub. I finished it off some wire wool. It came up to a fair finish. I had some spray enamel paint in the cupboard so I gave it a few coats, setting it aside between coats to dry. I cleaned the rubber boot. The unit must have been sitting in water for all the rust to be seen. I took the reservoir cap off and was pleased to see uncontaminated brake fluid slowly swishing about. I had picked up a new 70mm Jubilee clip during the day. I place the master cylinder where I thought it should go on the frame and fitted the Jubilee clip to loosely secure it in place. Then I put the rubber tank buffer in place and dry fitted the tank but no matter now a fiddled with the position of the master cylinder and buffer I could not make the tank sit correctly. I took the buffer off and low and behold the tank sat perfectly on the forward and rear tank mounts. I had another look on the floor for the spacer pin and the tank mount finger nut. I found both of them. I did the jubilee clip, fitted spacer pin and did up the hand lever cable. I left the brake light and fluid level sensor disconnected for the time being. Whilst I had the tank off I re-routed the throttle cables. I am get a dab hand at whipping the cable on and off the carbs. The throttle now returns to the shut position, if slowly.
With the master cylinder fitted the tank sat properly on the bike. During the week I had made my mind up to use the existing fuel taps as the ones that came with the ebay tank where rubbish. I took them to pieces and left the parts to soak in a cleaning solution. On Saturday and scrubbed and polished every piece of the two taps and put them back together and fitted them to the new tank. I got the new fuel hose out along with the fuel filters. I polished up the metal tee pieces that make up the balance tube on the fuel lines. I had to loosen the air filter casing yet again to fit the fuel balancing tube. Working from the bottom of each carb I cut the hose and pushed the hose on to the tee. Above the tee came the fuel filter, remembering to fit it in the correct flow direction. Then the last piece of hose on to the union at the bottom of the fuel tap. I did the job on both sides. It was a tight fit including the filters into the lines.
Now for the moment of truth. When I started the bike for the very first time it would not fire or run on the right pot. I hoped it was just a fuel issue which all the work on the tank and taps would resolved. I put petrol into the tank but something was not right. Petrol was pouring out of the bottom of the tank even though the taps were switched off. I put the fuel can down and rush round to far side of the bike. Petrol was gushing out of the top petrol tap union. I tightened it up with spanner but it made no difference. A closer look showed the fuel was coming out of the tank. I picked at the paint which opened flood gates. I managed to catch some of the fuel. when all the petrol was gone I took off the tank and found big hole in the tank which had been covered by paint. There was language! I cleaned up the garage. I had to take up the carpet in the garage and throw it out. It had soaked up the petrol. I opened all the windows and doors in the house, lucky it was a nice day, to rid the house of petrol fumes. H was not impressed when she came home.
I switched over the fuel taps from the "new" tank back onto the old tank. I put the old tank back on the bike, connected the fuel hoses and put some fuel in it. I slipped on the silencer and offered up a small prayer. I turned the key in the ignition, put the choke and thumbed the starter button. In two turns the bike burst into life. What a result. It was running a bit lumpy but after adjusting the throttle cables it was much smoother. I wanted to jump on it and ride away but I have no front brake, seat and a knackered rear wheel bearing. I had to be content blipping the throttle. The down side is that oil is pissing out the oil filer cover. I hope that is nothing but the oil light would not go out. I hope that is a electrical problem.
I am going start a new list on the blog...................jobs to do to finish.
