Lousy day!!

[spb2002]

I've had a Lousy day!

Started off okay... fitted new grip, levers and the Engine crash bars. All good so far.

I had a couple of hours, so thought id give the air filter a clean, and then moved onto fuel filter. Took tank off, turned it upside down on some rags... quick check, nothing leaking. Sadly i was wrong.... must have dribbled out, and now its wrecked the paintwork. gutted.

ALSO.... cleaned pump filter, replaced teabag with a new one.... put it all back together, and now it wont start at all. pump primes... theres no FI light, but no attempt to fire up. Lousy, lousy day....

[KiwiCol]

Sounds like you had some bad luck alright.    hate it when that happens.

As for not starting, it's gotta be fuel, as that's what you were working on.  Whilst in the tank, you may have dislodged the pressure relief clip & the pump is now just circulating fuel in the tank.  if so, wire it back in place. 

You could also try the flow rate first, save you pulling the tank apart again.  Take a hose off & measure the flow, the manual says 1.2L in 30 seconds.  Should also do a pressure test, but without the proper gauge it's not going to be doable.

[Hooli]

Bugger on the fuel, it shouldn't leak when upside down.

When you say no attempt to start does it spin over & not fire or not spin over? Some levers don't work the clutch switch properly so the starter won't work.

[Kiwifruit]

Have you checked the kill switch......ive been fooled by knocking that to the off position.

[seth]

My red and black tank did the same but I touched it up and put a cover on it .

[Del]

check the levers - if an aftermarket Chinese one then the contact for the clutch switch sometimes doesn't mate contact - put all the way out and try that - sounds stupid but I have been caught out with it

[seth]

Lever mod for aftermarket levers to work the clutch switch .
I superglued a small bit of old fuel pipe on the part marked in the picture .
As I'd modded emma's lever to help when filtering due to having girls hand with shorter fingers.

[Hooli]

I've done much the same on an aftermarket brake lever as it adjusted from 'too far in' to 'really really too far in'. Although I epoxied a bit of scrap metal on.

[spb2002]

Thanks for the comments guys. i'm going into the garage now, so i'll let you know how i get on. Hopefully it is the chinese levers, and its an easy mod. Dont really fancy pulling the tank again...!!

I'll let you know how i get on.

[spb2002]

Well, i'm pleased to say that it WAS the chinese levers.... on setting 3-6 starts up fine, setting 1-2, no go. i'll glue a packer onto it as you guys say.

Paintwork not great, could be worse though i guess. for now, i'll look at getting a vinyl sticker or something to cover it up. Does the petrol flap just unscrew with the seven screws? nothing i need to do from inside the tank?

[spb2002]

....And thanks again for everyones help!! very much appreciated!!

[seth]

It unscrew with just 4 of the screws .
Send me your address and I'll send you a set if stainless bolts for it after you've cleaned it up it'll look ok I'm sure .

[Hooli]

Aye it's the screws on the 'diagonals' sorta 1:30,  4:30, 7:30 & 10:30 if it was a clock face. Undoing all seven is fine, the others do nowt. I think the ones you don't need to remove are shorter so just check that if you pull them all out.

[spb2002]

It unscrew with just 4 of the screws .
Send me your address and I'll send you a set if stainless bolts for it after you've cleaned it up it'll look ok I'm sure .

Cheers Seth! - I'd already bought some, but hadnt got round to fitting them yet luckily, Thank you for the offer though!!

[spb2002]

Aye it's the screws on the 'diagonals' sorta 1:30,  4:30, 7:30 & 10:30 if it was a clock face. Undoing all seven is fine, the others do nowt. I think the ones you don't need to remove are shorter so just check that if you pull them all out.

Cheers Hooli. i'll take that off this week then, and brush it up. As Seth says, i'm sure they'll come up okay.