Not the Real '89 VFR -a mild custom

Of all the jobs in restoring an old bike, I had never before tried repairing ABS plastic and was about to undertake a very fast learning curve.
I quickly decided after feeble attempts "hot welding" the stuff that I had a lot to learn, so went seeking knowledge from Mr Google
I found someone using MEK (Methyl Ethyl Ketone) a solvent, to fuse the material together and it seemed easy enough that even I could do it.
A great solution, for me anyway - and with a bit of practice I even became good at it, and would recomend the process to anyone of reasonable skill
The photos following don't show anything like all the reairs, but settle on a very badly damaged belly pan, which had both holes in it - burned through by the exhaust no less. And in other areas the pan was badly distorted, once more because it had been seriously overheated - don't ask me how?
No "prior photos were taken unfortunately, but first pic. shows the front already with new cutouts applied and a piece of 3mm ABS sheet fused and clamped
to the outside awaiting an overnight cure.
Photo two is the reveal next morning with a rough up by sanding, just to tidy things a bit - but look at that distortion on the right side of the pan.
Following are a couple of the finished product, all straightened out with a heat gun, sanded, small touch up areas with "plastic bog" and all painted
I think you can see the difference in the shape - shown by the reflections in the paintwork. I am suitably pleased with the outcome
Every panel on the bike was busted, broken or holes in it and some mounting fixtures completely gone. Most would have said "Find another bike or fairing set" but I just fixed it all, learning as I went.
Before painting a SS perforated sheet was applied behind the "new" vents to keep out stones and debis, and the vents may now aid cooling down under?

 

Well. the VFR has been registered a couple of weeks now, on club plates which makes a big difference to the cost ($534 down to a little over $100 for the year) But it comes with limitations. Distance from home unless a a club registered ride is 30km radius, and then you must have a justifiable explanation - like service requiremens or such (no saying "I was just down to the coffe shop" (or pub.)
As a result of that and inclement weather I have only ridden about 500kms so far, but I can report they have been without incident, everything is running like clockwork - must be that VFR reputation? Oil level is still full, and no sign of smoke so dodged that bullet perhaps. My only concern at this point is the actual fuel consumption plus how much does the tank really hold?

Reseach says either 19 litres (5 gallons) or 17 lires (4.5 gallons). Whichever is probably irrelevent since my issue revolves aroung the fuel gauge and when the bike requires me to switch to reserve (caught me twice now).
I now top the tank off, record the kilometers travelled and at about 120 -130 kms, she will cut out unless I turn on reserve, after which I go straight to the nearest gas station and fill up. Seems all I can put in is about 9 litres when filled to the top -Why? Before putting fuel in I have peered into the depths of the tank and can see fuel, but it would seem well down, and short of having someone accompany me with a car and additional fuel I am at a loss for an answer.
When I first got the bike, someone told me the fuel gauge is notoriously inacurate But - when I fill it to the top the gauge reads full, and when it goes to reserve the gauge is indication this is about right. But 9 litres - what about the other 8 litres - are they still in the tank waiting for me to travel another 120kms?
Sure as hell doesn't look like it to me!
Exactly one week from today, I plan to ride with my motorcycle club (VJMC) on our annual ride to a central Queensland town called Monto, a round trip of about 1400km's for me from where I live. Surely I don't have to stop every 130km's and refuel - thats almost as bad as my H1 Kawasaki?
I know that so far, most of my ridding has been city stop -start, accelorate hard (having a little fun) but what sort of fuel consumption should I expect on country riding (perhaps "spirited" at times) but generally aound 100 km's /hour. (60miles/ hour)
Also, any thoughts about why the fuel goes on reserve with potentially up to 8 litres remaining?
Has the fuel pump maybe stopped working? (That just occured to me) - I shall check in the morning, doesn't seem logical but hey, what else is there?
If that is the issue why does switching to reserve appear to fix the problem?
So many questions..............

 

Checked the fuel pump - is working ok apparently (can feel and hear it with the sidecover off. I could not think why that may have been the problem anyway since the engine continued to run once switched to reserve.

 

That would be a very big reserve amount of fuel. Perhaps the internal piping for the "ON" circuit got manipulated at some point in its life and bent up.

Regarding the fuel gage, it is possible that it is being maxed out before the fuel tank is actually full. Perhaps try and stop at about 3/4 full and see where the gage sits.

VFR fuel gages (when working normally) are notoriously strange and pessimistic too. They will be full, or mostly full, forever and then start to plummet quickly. Like not linear, but parabolic in their action. Also, when I have started to feel panicky about where the needle is on my RC36s, there is still a pretty good amount of fuel remaining.

On my 86s, the time I go on reserve and when the fuel light comes on seems about right for what remains. 86/87 did not have a gage.

 

16L main + 4L reserve acc. to manual. I start looking for gas stations after 200km and rarely shift to reserve.