It has been a frustrating 2 weeks.
Lets start with progress
Adjusted the pilots to 1.75 turns out, the hesitation when blipping the throttle is 90% gone. I didn't take it for a ride however, so not sure if it is going to rev cleanly or not when there is load on it. It will be fine for the moment, will definitely be ride able. I am going to tick this one as complete. If necessary I will get back to this after roadworthy.
Revisited repairing the side panels. I used a product called Q-bond. Firstly I opened up the cracks (only picture of one panel, the repair was the same on both):
After I added the product, the next step will be to plastic prime and primer.
Are these the only productive things I have done in the past two weeks
Moving on to things that have been counter productive.
Oil leakage - The manual says to put sealant on the gasket's half moons where the cams are. I didn't so I need to redo that, the one is leaking. To myself: RTFM
I also haven't got around to fixing the cover.
I attempted to epoxy the tank. Unfortunetly the product failed. This is the before picture:
I can't seem to find the after pictures, but I know they are somewhere. You are supposed to have around 2 hours to move the product around the tank and to pour out the remainder. In my case it cured in around 30 mins, all in the one corner. Unfortunately it cannot be removed, the tank is now heavier and has less volume. Two sides were also not covered. I phoned the distributor, he is not sure what went wrong, and cannot give me an answer but did offer to redo the tank to cover the rest of it. It is going to be even heavier when it gets back
He added that he has never seen the product fail in this way. Just my luck.
I am not getting great service out of him either, I was supposed to have the tank back last week already. I hope he hasn't dropped it
I will edit this post once I have found the pictures, I stuck a webcam in the filler hole.
The one braided hose I ordered is leaking. I have received ok (I can't say good as originally they sent me two different looking ones) service from them, they are sending me another one.
Other service issues: I ordered a front brake switch, received acrylic nails instead and still haven't received my bar end mirrors, they are going to resend it.
I think that is it for this update...
Edit - one more thing, I had to redo the corner of the tank again, turns out there was more hidden damage