996 Issues...need a helping hand

[Cloner]

I'll post a few pics later (they're beautiful!), but I've found a few problems with a 2000 996 that's currently in my shop.  

First, the fuel pump had failed and I pulled the tank apart to figure out why.  I found that the owner had, before parking the bike four years ago without draining the tank or any other prudent preparations, replace the fuel hoses at some point with standard fuel hose, which had turned to jelly.  The tank was full of brown "gasoline" that smells like ass and the pump flange and other internal surfaces are covered in brown crust.  The tank's coating of black epoxy had mostly detached from the tank and I pulled it out in sheets.

Questions:  
What can I use to remove the brown crust from inside the tank.  It's only on the bottom surfaces, now, as the lining that came out protected the remainder of the tank from exposure.  The tank flange cleaned up with a brush, but it's difficult to determine whether or not the inside of the tank is well brushed/wiped.  Any thoughts?

Second, have any of you had more luck with one submersible fuel line than another?  I've never had to replace the stuff inside an injected bike's tank, so any specific recommendations would be appreciated.

Finally, should the inside of this tank be recoated with something to discourage rusting?

Now, on to issue number two.  The bike was stuck in first gear with the shifter down.  I expected to pull the left cover and find the spring broken, but when I got it off, the shifter popped up and all was well.  The pawl was slightly out of adjustment (approximately 1.5mm forward of center), so I adjusted it and buttoned everything up after confirming proper shifting.  I reinstalled the cover, tried to shift to first, but no joy.  WTF?

Could this be a lack of oil in the mechanism (since the bike hasn't run in four years)?  What am I missing?

Finally, the low beam headlight circuit nukes its fuse instantaneously upon turning on the ignition.  Relay issue?  I'll figure this out eventually, as so far I have devoted about ten seconds to it, but if someone has had this problem before it might save me a little time.

While I'm here, what are the odds the injectors will be ruined like the fuel pump?  Anything I can do to assure they survive if they're not dead already?  

All help is appreciated!

Cloner
ABQ, NM

[ducpainter]

Re the tank...

just POR it. The soap and acid treatments will remove the mung.

We use the NAPA stuff...Gates makes most of the stuff readily available anyway.

Bent shift shaft?

Put an FIM single injector chip in the thing...chances are you have two good injectors left, and they make better street bikes with that mod.

[Speeddog]

Yes, Gates via NAPA is the only stuff I've been able to source outside of OEM for immersion duty.
Only available in 1' pieces, BTW. 

POR15 is a good way to go for the interior coating.
I've not had a particularly grungy tank to clean with it, so no FHE there.
But DP's word on that is good enough for me.

Shifting... I'd go with the bent shaft theory.
I suppose the cover could be bent.
Try just loosening all of the cover bolts and see if it operates normally.
All of the shifting maladies I've seen were broken springs or slipped mechanism.

The injectors seem to be well protected by the pumps and filters.

[Cloner]

Yes, Gates via NAPA is the only stuff I've been able to source outside of OEM for immersion duty.
Only available in 1' pieces, BTW. 

POR15 is a good way to go for the interior coating.
I've not had a particularly grungy tank to clean with it, so no FHE there.
But DP's word on that is good enough for me.

Shifting... I'd go with the bent shaft theory.
I suppose the cover could be bent.
Try just loosening all of the cover bolts and see if it operates normally.
All of the shifting maladies I've seen were broken springs or slipped mechanism.

The injectors seem to be well protected by the pumps and filters.

That's what I figured on the hose, and the 1' limit shouldn't be a problem...just gotta get about three pieces, huh?

All of the shifting problems I've been exposed to were due to broken springs, so I'll try the bent shaft theory, as the cover looks pristine.

I'm actually more worried about four year old fuel having set up in the injectors more than trash.  Only time will tell.

Thanks for the thoughts, gents.

S

[booger]

For gummed-up injectors, there's always this guy.