Saturday I picked up the forks from Eurosport with the new seals and dust covers installed. Sunday Tom came over and we commenced the reconstruction of the front end. We put new fork oil in, old progressive springs, washers and spacers and buttoned up the legs. I had marked the insertion depth of the forks in the triple tree with a Sharpie marker and used the line I drew to set the depth of the left leg. The mark on the right leg had been erased by Eurosport so I got my electronic calipers and measured the left leg and we set the right leg using the calipers. As we set about putting the spacers and clip-ons on we determined we had not accounted for the routing of cables and lines from the clip-ons and we had to lower the forks in the triple tree to reroute the cables. Typical. We just removed the brake calipers and loosened the clamps to slide the tubes low enough to squeeze the cables and wires around the tubes, then slid the forks back up until the left leg mark was flush and retightened the clamps, viola cables properly routed. We had the front end complete and moved on to reinstalling the intake snorkels, which required some tie-wraps to clamp them to the frame. Then it was time to put the fuel tank on so we unhooked my aux tank and set the fuel tank in place. Connected the two fuel lines, vacuum line and plugged in the fuel gauge lead when we noticed gas dripping from behind the fuel selector knob. Not cool. I removed the selector knob and sure enough there was gas dripping out. I backed out the two lock screws that are the selctor travel stops and pulled the knob hub out. The seal at the back of the fuel tap (petcock) had a gash in it. No big deal, get a rebuild kit ordered up that included that seal. Problem. No rebuild kits available in the US. So tomorrow (because most motorcycle shops are closed Mondays) I'll check with Eurosport and see about getting a complete new fuel tap. Until then the project is on hold........again......
