Rebuild - Hardest job yet? - BUT SHE LIVES !
 

Two soddin hours last night to complete what should of been a simple job to do with finally rebuilding my tank (amongst other things)....

On reflection its probably the most frustrating thing yet in the two months I been working on the bike:

Any idea what it is yet, kids???
(Best Rolf Harris voice opional).....

Carb overhaul ?......Nah Easy

Balancing Carbs ? .... Not too bad

Tank relining ? ..... Just follow the instructions

Nope - Replacing the damn tank cap outer seal ring !!!

No wonder my last one had broken in situ; it was so tight putting the new one on that I didnt actually fit it correctly and left it underneath the very outer most ring, where it should be.

I can only imagine the designer was in a sadistic mood the day he designed this beauty.

In addition to keeping the ring in place (with four hands) the dump tube has to be fitted to the underside of the cap body (another two hands) and then it has to all be fitted without disturbing the darn ring :mad:

After all that I didnt align the cap up correctly with the tank either! But that can whistle. I'll leave it as a reminder of 'artistic engineering'.

Frank.

Heh, had to do this myself the other week - trust me that it's just as hard with two pairs of hands because the extra set *always* gets in the way.

In the end I sat and stretched the ring for a good five minutes before rebuilding. It's then a case of slowly slowly pressing the ring down and working round the grub screws. I used a rubber mallet (with the head uppermost) and pushed it down with my chest, leaving two hands free to get the screws in.

Not the most technical method, but it worked!

I've had to do this 5 times in the last 2 months. It gets easier . . . . . .

I've found the best way to to use a very small amount of grease on the edge of the tank. This lets the rubber seal slide into the gap nicely. A few taps with a rubber mallet then seat the whole thing tight in the hole and you can get on with doing the irritating little grub screws up.

Glad its not just my ineptitude then !!!

But why didnt they make a seal to fit in the tank first - THEN the cap base could be pushed into it?

Ho hum - done anyways - new headers are the latest battle :(

Why does very little fit straight away 'out of the box'.

F

What would be the fun in that!? :P

Haaa Haaaaaaaa....she lives!

Had to take an angle grinder to the header pipes so the SL exhausts would fit and there will be more on a similar theme when my Carbon cans go on but, she runs a treat - instant start on the button - I'm in Love again :devil:

Frank
DSC Webteam and Supersport fanatic!

well done frank- great feeling knowing it is all your own work!

Many thanks - rebuild highlight to follow in due course ( hopefully post - MOT !)

Frank