My painter has recently finished not one, but two R/W/B 2d-gen projects for me. That's a lot of pieces to keep track of but it's all safely back home and ready to go back on the bikes — well, some reassembly required. Here, we'll work on Project 38, and that begins with the fuel tank.
We need to reinstall the fuel cap, petcock, fuel level sensor, heat pad, and front/rear rubber mounts.
(Below) The fuel cap is straightforward, but this cap required lots of massaging with Autosol polish to remove spotting on the surface. The cap's anodized finish can be difficult, sometimes impossible, to polish but in this case it worked pretty well. TIP: If your cap is reluctant to close without excessive force, it may be that the rubber seal has hardened with age and exposure to fuel. I've found that applying heat to the seal and then closing it will allow everything to fit nicely. Cover the opening to protect the finish and avoid gas fumes.
(click on images to enlarge)
We need to reinstall the fuel cap, petcock, fuel level sensor, heat pad, and front/rear rubber mounts.
(Below) The fuel cap is straightforward, but this cap required lots of massaging with Autosol polish to remove spotting on the surface. The cap's anodized finish can be difficult, sometimes impossible, to polish but in this case it worked pretty well. TIP: If your cap is reluctant to close without excessive force, it may be that the rubber seal has hardened with age and exposure to fuel. I've found that applying heat to the seal and then closing it will allow everything to fit nicely. Cover the opening to protect the finish and avoid gas fumes.
(click on images to enlarge)
Next I'll tackle the petcock assembly. I'll install a new petcock, but years of neglect usually leave the shiny bits dull and spotted. First, a cleaning, with special attention to the recessed lettering to remove built-up wax which had obscured the black letters. Then a hand polishing with Meguiar's Ultimate Compound brings this bit of bling back to its original look.
(Below) Next, I install the low fuel level sensor with fresh o-ring, followed by the heat shield, gently bending the holding tangs. New frame cushions are put in place. For the original location, look for a paint shadow where the old cushions were located.
Lastly, a new front mount rubber cushion is slipped into place and the rear rubber fitted. This is a California-spec tank, so I won't forget to put a vent hose onto the tank's forward fitting. This tank is ready to be installed onto the bike. Next, I'll prepare the side fairings.
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