HAHAHAHAHAHAHA!
It never goes that way, does it? Customer bike, not my exact cup of tea but it isn't my bike either. He loves it.
He is also deployed very far away for most of the year and just wanted to be able to come home, jump on his bike and enjoy it. He doesn't have time to learn how to do it himself, has a family. So I said, "Sure, we'll fix your bike for you man". And I don't regret it, but it has been as I said to him, "like an onion", and the more we peeled it the more stuff we found it needed. I shouldn't have been surprised.
It was leaking a ton of oil...
...much of which turned out to be from a missing oring around the oil filter base, but once we pressure washed that off and started it, in fact oil was leaking from all over the engine.
The front brake seal had let go, was leaking fluid steadily.
...so we pulled the caliper apart, vapor blasted the flaking paint off and left it bare, replaced the seal and the brake lines, substituting a 400F upper brake line to work better with teh Clubman bars (a good solution). It had some weird aftermarket MC, so we just opted to replace that with an inexpensive repro unit from 4into1, both cheaper and faster than chasing parts for his.
Carbs were gummy and bowl screws were stripped, so the bowls had been cemented on.
We stripped and cleaned the brass from the bowls and ultrasonic cleaned the rack, put it back together with new orings and gaskets and bench synced them. Checked the fuel level with the clear tube test, good to go.
The oil pump was leaking, so it got one of Elan's kits to replace the orings and everything was cleaned and measured while it was apart. Should be good as new now with better oil pressure too.
The starter oring (and every other oring) was as brittle as plastic and shrunken and not sealing. We skinned the starter and found the seal had failed and there was oil within it. Cleaned it all up, lubricated it and reassembled it with a new seal and oring and a new wire bootie for that bare hot lead.
But wait, there's more!
...
