From 1984 Voyager to a street fighter

As of now I have few issues.
1. clutch, look like it is not pushing the adjustment screw deep enough and the clutch is not fully engage
I tested yesterday with the cable and it's working fine. as of now I will go back to cable and revisit in a later time
2. the gas tank was rusty, I cleaned it really good but look like I have lots of rust at the bottom, the full filter get full of rust after couple minutes
I tested with external bottle and it stay clear, so its defiantly from the tank.
3. look like one of the thermostats that connected to the DFI system is not working, look to me like its too hard to start the bike when its cold and its not working smooth after it getting hot. I will go into this issue after I have the gas tank clean and clutch working.

below is the fuel filter after couple min,
It was completely full with rust the first and second time
this is after the third time I took it apart and clean

Might be worth checking the non return valve in the tank is not stuck closed. That would cause overpressure in the fuel rail and bad starting/running.

If your tank was full of varnish, then it is possible that the varnish has encapsulated the rust. When you put fresh gas in it, some of that old varnish will dissolve which will free up some of that rust.

Try this::
1. Remove the tank and drain it completely,

2. Remove the petcock and manually clean it.

3. Plug up the hole for the petcock, fuel return and vent.

4. Dump one box of baking soda into the tank. The kind that you might use to keep your refrigerator smelling nice inside.

5. Dump in a gallon or so of vinegar It will foam up a LOT. Just use el-cheapo white vinegar that you can get at most any grocery store Try not to get any vinegar on your paint, so, pour the vinegar in slowly. Plug up the fuel fill.

6. Slosh the tank around a LOT.

7. Let it sit for an hour or so. Slosh around a LOT.

8. Drain the tank. through a cheese cloth and see what kind of crud comes out.

9. Flush out with fresh water and drain again into cheese cloth. Put your hose on full blast when you are flushing out the tank.

Repeat as necessary from step 3 until no more crud comes out.

Dry the tank thoroughly. You can use a hair dryer or run your car exhaust through it.

Etch and seal your tank.

Thank you guys,

the plan is to clean it again this weekend
maybe seal it after, what do you think about por 15 sealer?

I used the POR Tank kit on a Honda tank more than 20 years ago. Still holding up just fine. Comes with everything you need to clean, de-rust, and seal the tank. Very happy with the results.

I would be surprised if that fuel filter flows enough to keep up with the flow demands of the fuel injection system, it looks more suited for the much lower flow of a carburetter bike. When you see the size of the original fuel filter you know what I mean. Do you have any fault codes in the DFI control box window? I also wonder if running without air filters is affecting the running.