So I eventually got the tank cleaned up, wax and grease remover softened the mess enough that i could scrape it off with a plastic scraper.
20200523_145014R by
JAFA851, on Flickr
20200523_145708R by
JAFA851, on Flickr
This is why I had to get that out, so I could get the fuel level sensor out.....
20200527_143253R by
JAFA851, on Flickr
Both level wires broken, both power wires for the pump broken insulation and shorting together. All because no one though to sit the tank on blocks when they've taken it off previously....
I was sure I'd bought a new level switch a while back, the newer short stubby style with the later version plug ( the only style level switch available these days ), but can't find it anywhere, and it's not correct anyway. So I've ground and filed away the resin on the existing unit to expose enough decent wiring to graft on some new wires
20200602_122600R by
JAFA851, on Flickr
20200602_122549R by
JAFA851, on Flickr
Then Mike in the electronics workshop at work unpicked the crimped sections on the 4 pins that go into the plug, and recrimped new wires into them, and soldered and heat-shrinked the wires onto the level sensor.
20200604_110934R by
JAFA851, on Flickr
Now all I need to do it redo the resin around the cable and get it back to shape, put some sleeving over the cables ( I have the correct size sleeving ready to go ) and fit the pins back into the plug.
***** Does anyone know where I can get the right angled rubber boot that goes over this?****
Then I'll get a new o-ring that goes under the big nut that screws the whole thing onto the bottom of the tank because the current one will probably leak......
20200604_111016R by
JAFA851, on Flickr
While the crimpers are out, once I unravelled the 3/4 of a turn of rooted electrical tape "mostly" covering the joints, you find this nice example of the standard of workmanship of the previous owners. I suppose at least the quality here matches the quality all over the rest of the bike....... Anyway, these 2 are the power feed ( red ) to the fuse box that is just in front of the tail light, and the brown goes out to something I can't remember.
20200603_100455R by
JAFA851, on Flickr
So I've unpicked those wires out of the crimp lugs too, sourced new correct size and colour wires, and once I've cleaned the green fungus out of the lug on the left, can recrimp them with new wires and put them back into the fuse box and the 4 way plug on the other end, and hopefully there won't be any electrical fires...........
20200605_070045R by
JAFA851, on Flickr
Over and out for tonight