Replacing a fuel tap ... issues

[Asian Boss]

The fuel tap leaks on my 1984 XL200R when in the reserve position. I thought I'd replace it.

I bought a replacement.

I took the tank off and removed the old tap. The plastic filter tube had broken off and was stuck in the tank. I pulled it out with pliers. Quite a bit of liquidy rust came out too.

I tried to fit the new fuel tap. The plastic filter tube was just to big to go in. I ended up pulling it off and seeing if the tap would fit without it. It didn't the thread where the tap joins the tank was different.

I'll try and get another tap with the correct thread.

Is the plastic filter tube essential? It has an external in line filter (which I'll also replace anyway).

How worried should I be about the rust in the tank? When the fuel tap was off I held it over a big measuring jug and some fuel flowed out. It was rusty at first but seemed ok after a bit.

[cheb]

Have you a borescope for your smartphone, or can you peer in with the aid of a torch? Post up a photo looking down the filler hole.

This is what works for me:
Put a short length of chain in the tank and shake it about until bored. String ties to the chain makes it easier to fish out. Rinse it out with running water. Tape some newspaper to a suitable stick and poke it into the tank with both the tank and stick at a suitable angle to adsorb any remaining water. Swill the tank out with some paraffin when dry.

I don't usually put the tap filter back on, I prefer an inline filter. Fit a transparent in line filter and you can monitor the amount of crud as it comes out. Run it on reserve until you are happy all the loose crud have come out.

What size thread is it?

[Asian Boss]

Thank you.

I don't think the inside is too rusty. There was just some which was dislodged when I pulled the filter around the old tap out. I will have a look in the top and try to take a photo.

I'm not sure what thread it is, quite fine! The one I bought (for 250 Superdreams) was too coarse. It's quit hard to measure as I put the old tap back in place.

[JackyJoll]

I run with no gauze on the tap and fit an inline filter in the hose.

[maccecht]

Just replace the O ring if you can get one. David Silver may have one

[Asian Boss]

Thank you both.

I did think about mending the existing tap but it doesn't obviously come apart. And replacement ones are fairly cheap.

I've ordered another now. With I hope the correct thread. Also new fuel hose and fuel filters.