OK.  drained the tank, let it dry, opened the hole, and applied some liquid weld.  after 3 hours, added fuel and waited to see what happened...NO LEAK!  not sure how lobg this stuff lasts, but it seemed to do the trick.

also, i think the problem with flooding has to do with the "on" and "res" lines being switched.  gonna investigate further later. 

horn and lo-beam still aren't working, not sure why! maybe a fuse?

other than that, i took her out for a ride tonight!!!  runs and shifts well enough for me.  has a nice idle when the fuel is flowing properly. 

thanks for all your help and suggestions, i'm 90% there!

How did you paint your bike? Did you use a spray gun or spray cans? How did it come out?

i used cans.  2 coats with the paint and 1 clear.  it came out OK, but needs a wet sand before the second shot of clear.  haven't done it yet because of the high humidity lately.

took her out again yesterday.  runs fine when in gear, but not getting enough fuel at idle.  I have to switch the petcock to PRIME for 5-10 seconds with it running, and then switch back to RUN before the gas poors out.  Then it's fine again for another 2 or so miles or the next long light.

17.6 miles and counting...

still having the fuel issue.  i think it's the petcock, and not the carbs.  took it to my local shop and he said the petcock has a small filter that needs to be cleaned, could be impeding the fuel flow in RUN.  suggested i take it apart and clean it.  anyone tried this?

i also looked through the manual on the carbs: not much in the way of adjustability.  How to you tune for idle, etc?  i'm used to seeing a set screw or something; not familiar with Mikuni...

The idle screw is the big screw with a plastic knob that sticks down between the carbs. Warm her up, then adjust the idle with her running. I don't remember which way is which.. you can either search here.. or just try it...

i'll give it a whirl when i get home.  found more blistering on the left side of the tank.  the PO did a poor job of repairing the tank.

So, the tank is a gonner.  The POR15 treatment did not work and is peeling from the inside.  Not sure why since I followed the directions exactly. 

I used a wire brush and grinding wheel to remove all the PO's bondo patchin to reveal a HOST of small holes and some biguns.

Coyote, how soon can i get that tank???

POR15 peeling after 2 weeks.


Pinholes in tank seam



BIG Hole in tank

OK, for those interested in my saga - I finally got the tank from coyote in working condition.  Took the carbs apart to see what was inside and realized why the bugger was flooding.  the float needles were installed in the wrong valve assemblies.  one needle was jambed into a jetway for the idler.  no wonder it would lose idle!

i replaced the valve assemblies and seals and will try it out when i get my new fuel petcock next week. 

what's the really small o ring for?  i know where the other 2 go.