Please help a noob....my gas tank won't quite fit....

[Avpdrmr]

I have recently finished (well almost finished) building what started life as a 1999 Val Interstate.  It was involved in a bad crash and has been rebuild into a street cruiser.  The new frame was from a 2000 tourer.  My research told me the frames between the 1999's and 2000's were the same, but now that she is (almost) done, the tank won't fit.  It is the original interstate tank from the 1999.  My problem is, it hits the airbox lid.  Yes, I did look for all the ways I could figure to lower the lid/airbox.  The bolt hole for the airbox lines up with the tab on the frame.  All the rubber air runners are all the way down on the carbs.  I didnt have the carbs off, but a mechanic did.  One would assume the carbs are back where they are supposed to be.  I'm not above modifying the airbox lid to gain the clearance, but if I am missing an easy fix, I would always rather do it right.  Below is a link to my facebook albulm with pics of the build and the (almost) finished bike if anyone is interested.  Thanks for any and all help anyone can provide!

Shawn
http://www.facebook.com/album.php?aid=2163&id=100000169404147&l=b42e9010b5
the finished pics are on the 2nd page....

[Foozle]

If memory serves, there are a pair of ribbed rubber cushions (one per side) that fit on the upper frame rails directly underneath where the tank sits.  Could something this simple be your problem?  Terry

[Chrisj CMA]

I was going to say same.   I didnt see the cushions in your pictures.......Ill try to find a pic and post it

[Avpdrmr]

Sorry, forgot to mention, the ribbed rubber pads are there and in the correct locations, but when i look under the tank (with the airbox/lid in place) I can see the tank no where near the pads.  I can actually see the tank resting on the airbox lid....any other suggestions?

[Chrisj CMA]

I have a thought.....I have never removed the airbox, but is it possible that you have the tubes that connect the carbs to the box reversed or something so maybe an angle is backwards makeing the box higher than it should be???

[Avpdrmr]

If I remember (it was pretty late) the runners are pretty well glued into place, but I will surely check when I get off work....

[Foozle]

I've never had my airbox off, either - mainly because everyone complains that getting it back on is an exercise in futility.  As a result, I suspect this is where the culprit lies.  Sorry I can't be of more help, but I'd exhaust all the possibilities here before looking to the carbs, frame, or tank.  Terry

[Avpdrmr]

It was near impossible to get it back down on the carbs, I will never have that thing off again! (unless I have to to fix this problem I guess!)  Thanks for all the ideas, and keep them coming everyone.

[Ricky-D]

If the airbox is down all the way, I wouldn't worry about it.   That is a very tight clearance area to begin with.  A lot of guys shim the tank higher up anyway.  Put a little thicker pad on the frame rails and shim the mounting bolt brackets and be done with it. Nice bike there!

***

[John U.]

It was near impossible to get it back down on the carbs, I will never have that thing off again! (unless I have to to fix this problem I guess!)  Thanks for all the ideas, and keep them coming everyone.

I needed an inspection mirror and flashlight to get the rubber air tubes seated correctly on the carbs. They tend to get distorted in the rear where you can see. Although they appear to be seated they hold the airbox higher than it should be.
Good luck

[Jeff K]

If the airbox is down all the way, I wouldn't worry about it.   That is a very tight clearance area to begin with.  A lot of guys shim the tank higher up anyway.  Put a little thicker pad on the frame rails and shim the mounting bolt brackets and be done with it. Nice bike there!

***

If the tank won't fit, the air box is not installed correctly. The tank is where it is, the air box must be sitting to high.

[Oyeaa]

Very sweet paint job.

Sorry I have nothing useful to add.

[R J]

I repeat what Jeff K says........

Airbox is not properly installed...........   Probably one of the rear tubes holding it up......  That was the problem on mine way way back about 12 years ago.........

[MP]

+1 on the airbox not installed correctly.  It is not set down right.  One or more of the tubes is holding it up.  Sorry!
MP

[Avpdrmr]

Thanks for everyone's help!  Last night I did remove the airbox again (hopefully for the final time! What  a pain!) and upon more diligent re-installing the tank fits! It was by no means a drop her on and go as it took a bit of "encouragement" to get everything to line up but on she is.  Even got the bike out for her first test ride.  Here the story turns sour.  The bike only has first gear and neutral. Any ideas?  Im towing her into the shop this afternoon, discouraged, but not giving up.  I also appreciate everyone's comments on the paint.  It surely has been a labor of love.

[Ricky-D]

Sure, I'd suggest looking at the shifter pedal and connecting linkage.  Sounds to me it could be hitting something (exhaust pipes) or just bottoming on the frame. Something like that.

***

[Jeff K]

Sure, I'd suggest looking at the shifter pedal and connecting linkage.  Sounds to me it could be hitting something (exhaust pipes) or just bottoming on the frame. Something like that.

***

+!

The shifter peg is hitting the pipe. Without a doubt.

[MP]

Easy to check.  Rotate the peg one notch on the splines downward, and see if that fixes it.  Bet it does!
MP

[Larry]

Very sweet paint job.

Sorry I have nothing useful to add.

I agree on the paint, that hammered look is very nice. May have to rethink my black and chrome colour scheme! Ya, I know I spelled colour  not color, those Canadian's EH!

[YoungPUP]

Sorry Way off of the subject, and if you don't mind me asking but what did you use as a finish for the valve covers, and to black out the exhaust, as that looks Awesome!