Glad it all worked out Guys:
Jonny / Glyn:
Maybe it was just a tight fit on my Bro's bike or a poor fit between threads, in any event I filed the outer circ of the washer quite a bit and then wrapped it in PTFE tape. Overkill perhaps but it worked a treat.
Derek:
Welcome back mate, youve been missed!
I'd never dream of taking any sort of credit for your sensor work or external fuel filter mod or headlight suggestions or......
bl00dy 'eck time to stop
Cheers - Frank