First step of the POR-15 process

The inside of the tank before I started.



What came out of the tank.
What came out of the tank.



After. Looks like I might need to do it a few more times.

I didn't get a chance to do much on the bike this weekend. I did work on the engine starting issue and it looks like I may need I new starter magneto switch which cost about 75 bucks. I am going to do some checking with meter before I purchase a new one. I also went and got some new vacuum and gas line. I am going to make the tank the number one thing this week and after looking at the instruction it will probably take all week. I will post some pics of the tank repair along the way.

Well I finally got the gas cap open this weekend. Had to drill a hole in the top and unscrew the screw that was under the cap. Then I removed the the allen bolts and the cap fell out. After it fell out I found out why it was locked up. I couldn't even move the lock with pliers. Anyway time to get started on the POR-15 tank coating.

The old gas cap

hole drilled to get it open

No real work on the bike tonight, just went over the wiring diagram in the manual. I think my starting problem may be related to the bypass job that was done by the guy my brother bought the motorcycle from originally. He removed the kickstand switch that kills the bike if you try to take off with the kickstand down. The plan for this weekend is get the gas cap on the tank open. I ordered a new one and should be here in a day or two. I will post some pictures of the gas cap after I shoot it with 9mm, it has really been a pain.

Finally some good luck. Hooked the battery back up today and tried to see if I could get it to start. Turned the key on hit the start button and nothing, I held the starter button down and started moving the wires around near the start solenoid and fuse box and dang if it didn't try to start. So it looks like a lose wire or bad connection some where but at least the motor is not ceased up. Think I will drink a cold one tonight.

Finished fixing the electrical wiring except for the sparkplug wires this weekend. Also changed the 10 year old oil and filter. Got a new battery and charged it up. I decided I would put the new battery in the bike and see if it would turn over. Turned the key on and all the lights came on, flipped the kill switch to run and hit the starter button and nothing happened. So I guess I have some more wiring issues that I don't know about. Maybe better luck tomorrow.

Brake Fluid after sitting 10 years

I was able to work on the electrical system yesterday. Got most of it fixed except for 3 wires. Two go to the fan on the radiator and one I am not sure of. I can go without the fan to see if it will crank but I will need to fix the other wire. I need a 2.8mm male pin connector to fix it so I am trying to find one locally, if not I will have to order some on-line. I still can not get the gas cap open so i still have that issue to fix too. I think I might go ahead and drill the thing out and be done with it. Not sure what I am going to do today, may just relax and get ready for the super bowl.