Zongshen 200GY-2 Tank Plastic Mod
 

I have always believed that Zongshen went a bit overboard with the tank plastic on the Sierra 200GY-2 motorcycle. Also, I have always disliked the two heavy, metal pieces that attach to the motorcycle’s frame and support the tank plastic in front, simulating a radiator shroud.

I am always looking for ways to lighten, and improve, the Zong. When one of the plastic brackets that support the front of the tank shroud broke off, I decided to trim away the excess tank plastic. This modification has also allowed me to get rid of the heavy, unnecessary metal brackets that supported the front of the tank shroud.

Here is a photograph of the original tank plastic

http://i442.photobucket.com/albums/q...oirTrip061.jpg

Here is a photo of my new, trimmed tank plastic.

http://i442.photobucket.com/albums/q...ortPeak012.jpg

I am still considering trimming a bit more from the tank plastic. Namely, I could eliminate the bottom plastic fin, as shown below.

http://i442.photobucket.com/albums/q...012Trimmed.jpg

Cal25 has made a fine suggestion to eliminate all the fins.

http://i442.photobucket.com/albums/q...d/CalsTrim.jpg

Therefore, I have created a poll. Which do you prefer. The original tank plastic, my current configuration with three “fins,” the projected configuration with two “fins,” or "no-fins?"

While you ponder your decision, here are a few more photographs of my current configuration, taken from several different angles.

http://i442.photobucket.com/albums/q...ortPeak018.jpg

http://i442.photobucket.com/albums/q...ortPeak016.jpg

http://i442.photobucket.com/albums/q...ortPeak033.jpg

http://i442.photobucket.com/albums/q...ortPeak030.jpg

http://i442.photobucket.com/albums/q...ortPeak028.jpg

Spud :)

your tanks pics arent showing up here at work but that could just be the filter. i myself have considered removing the plastic around the tank entirely but i do like the size it seems to simulate .

i have thought of adding a bigger tank with the emphasis on height but i dont know what to use. hopefully i will be able to see your pics on my computer at home.
shawn

Got to say the trimmed panels look naff, nice view by the way:)

Jonathan.

http://www.urbandictionary.com/define.php?term=Naff

I'm glad you enjoy the view. :lol:

Spud :)

Spud, is there an aftermarket tank available that doesn't use the side plastic? I'm thinking about one of those extended-range units. Maybe one of those in black would meet your needs, unless you can find the same orange.

I am not a fan of the fake shrouds on these bikes either. Cutting the excess off would make the bike slimmer in the tank area thus reducing wind drag I would imagine. If there was a clean way to cut back all the way back to create a smooth line from the upper front of the tank cover to the lower rear, that would be the best for me. However I think the ugliness of the plain black tank under the cover would show thru.

What are you using to cut it with? Something like a hot knife might work well.

It's interesting you should mention the aftermarket tank, WG. ;) Indeed, I am currently considering that option. :)

Spud :)

I would have left things as they were, but one of the brackets on the tank plastic broke off. Also, I was glad to lose the extra weight from the metal pieces that attached the tank shroud to the bike's frame. ;)

In answer to your question, Cal, it is not an easy task to cut the Zong plastic. The Zong plastic is thicker, more brittle, much harder to cut, and definitely inferior to the plastic found on Japanese motorcycles. :( The brittle plastic allowed vibration alone to break off the shroud's connector after 14,000 miles.

Incidentally, I consider the wide, soft seat on my Zong to be one of this motorcycle's nicest features. :D I frequently ride my Zong for 300 miles a day, and the wide seat makes these excursions bearable. I would remove the tank plastic entirely, but this would leave a space between the Zong's seat and the fuel tank. Also, the wide seat extends too far past the sides of the fuel tank without the plastic tank shroud in place. :(

You offer an excellent alternative when you suggest trimming the plastic all the way back from the front of the fuel tank to the lower rear. However, I can't think of a good tool that would accomplish that task. :( I used a hack saw and Dremel tool to remove the plastic on the front of my tank shroud; it was not an easy task. :( I don't think a hot knife would work well cutting this plastic. Perhaps the best tool to use would be a coping saw. :?:

Spud :)

I think it might look, and weigh, best with no shrouds at all. Like to see a pic that way. It certainly looks lighter.

Spud, how do people who don't live out West survive?

A coping saw isn't a bad idea. You could also try a drill saw, although you need to move relatively quickly, or the plastic just turns to goo. Drill saws (as the name implies) are really just serrated drill bits that allow lateral cuts rather than just vertical drilling. You'll likely find them at your local Harbor Freight.

You could also try judicious use of a flap disc on a 4 1/2" angle grinder. Sneak up on it, and you could sand away all the offending material. Stop short of your final cut and hand sand the last bit. That's all I can come up with.

A mask is advisable, since there have been several reports of lead in plastic that comes from China.

Coping saw would be the best bet I suppose. I added a line for a proposed cutting line to your pic. The line could also be leaned farther forward or curved forward.

http://i168.photobucket.com/albums/u...le/optiona.jpg

Also, your kickstand is going to get even heavier if you make the switch to a 21 inch front wheel. :D

The tank plastic merges with the side plastic, while also filling a space between the seat and fuel tank. In addition, the tank plastic provides a wider base for the Zong's comfortable saddle. :)

http://i442.photobucket.com/albums/q...Plastic005.jpg

http://i442.photobucket.com/albums/q...Plastic006.jpg

http://i442.photobucket.com/albums/q...Plastic002.jpg

http://i442.photobucket.com/albums/q...Plastic003.jpg

Here is an image of the metal brackets formerly used to attach the front of the tank shroud to the motorcycle’s frame.

http://i442.photobucket.com/albums/q...rackets003.jpg

Finally, here is a photo showing how the tank plastic merges with the side plastic, while also providing a wider base for the Zong’s saddle.

http://i442.photobucket.com/albums/q...Plastic011.jpg

Spud :)

OK, you do need some plastic, for looks and function. I'd stick with the cuts you've already made.

Thank you for your suggestion, Cal. Here is a proposed trim I could make rather easily. :)

http://i442.photobucket.com/albums/q...d/CalsTrim.jpg

In effect, this trim eliminates all three "fins," creating a "no-fin" option. I will add your idea as another choice in the poll. :)

Spud :)

8O what you doin spud ? :lol: From what has been shown, I like the original still the best.

Your vote is currently in the lead, DR. :lol:

I can always return to the original equipment by ordering new plastic. Since the plastic mounting tab broke off, I would still need to replace the original plastic in any event. Therefore, I decided I might as well experiment a little bit. ;) After all, experimenting is just part of the fun in owning a Chinese motorcycle. :)

Spud :)

Spud, I'm going to need an aftermarket tank option before I can vote. :lol:

http://inlinethumb49.webshots.com/42...500x500Q85.jpg

Maybe a cut but not as much, Kinda squareoff the edges and make it match the sharp edges the rest of the bike has :? How do You like that fine art work? :lol:

That's a good line. Anybody else have photoshop experience that can clean that up a little?

That cut deep man :lol: My windows paint skills don't cut it do they? :lol:

Your art work is very nice, AZ. :) However, your sections won't work, because the mounting tabs at the front of the tank plastic would be cut away, leaving the front of the tank shroud unsupported. :(

Spud :)

Ummmm Your cuts are farther back...What's supporting it than? :wink:

Can you fabricate a new pair of mounting tabs? It might take some creativity, but that's nothing new to you.

I didn't mean any offence. It just looks like you held a paintbrush in your mouth. :lol:

I'mma go cry now :lol:

:lol: :lol: :lol: :lol:

I like factory still.

After my cuts the tank plastic is much smaller, weighs less, and has less wind resistance. My current tank plastic is supported by two bolts at the rear of the shroud, and the gas tank itself. Movement in the horizontal plane is further limited by the filler neck of the gas tank, which protrudes through the tank shroud. Movement in the vertical plane is limited by the saddle, and the rider's weight upon the saddle.

If one really wanted, he could make your proposed cuts, and he would probably not encounter any difficulties with shroud support. However, the view from the front of the motorcycle would not be esthetically pleasing without the fake "radiator" present to conceal the "elephant ears" of the flaring, unsupported plastic. ;)

Spud :)

im with jim i even like the factory size tires if i could afford them :cry: (but im trying to get that changed)

Upon further reflection, I believe your proposed section lines would work, AZ! :)

As you can see below, the mounting tabs on the Zong’s tank shroud are probably located inside your proposed section lines. :)

http://i442.photobucket.com/albums/q...lastictabs.jpg

Therefore, one could trim off the lower “ear lobes,” and square off the front of the Zong’s tank plastic. :) However, the front section line would extend slightly forward of your proposed line, to allow the metal “radiator” brackets to mount to the frame. :)

http://i442.photobucket.com/albums/q...tenance086.jpg

Personally, I would not modify the tank plastic if I were keeping the metal “radiator” brackets. However, you offer a very nice, valid option, if someone wishes to eliminate the “ear lobes” from the Zong’s tank shroud. :)

P.S. I love your artwork; it reminds me of the French Impressionist School. :lol:

Spud :)

Thank you for the kind words, WG. :) However, it appears that it would not be necessary to fabricate new mounting tabs to accomodate AZ's proposed section lines. :)

Spud :)

I am not ignoring your response, WG. :) I have done a significant amount of research regarding the aftermarket tank options for the Zong. However, I need to experiment a little before I present my findings in another thread. :)

Spud :)

Once the mounting tab broke off my tank shroud, I decided I had nothing to lose by experimenting a bit with different shapes.

None of the modifications I have made to my Zong are irreversible; I can easily return my motorcycle to stock form, if I desire. :) Therefore, I can easily buy new tank plastic, and return to the original configuration.

I am going to take Cal25's suggestion, and make the following section. I will post photos after the cutting is done. :)

http://i442.photobucket.com/albums/q...d/FinalCut.jpg

The retouched photograph shown below should approximate the final result. :)

http://i442.photobucket.com/albums/q...edFinalCut.jpg

Spud :)

I completed my tank plastic cuts. In addition, I decided to trim the rear side plastic as well. :)

Here is a photo taken in an Idaho wheat field.

http://i442.photobucket.com/albums/q...dValley038.jpg

This photograph was taken with an Idaho thunderstorm occurring in the distant mountains. Fortunately, I avoided getting wet. :)

http://i442.photobucket.com/albums/q...dValley069.jpg

Here is a view from the 4 o’clock position.

http://i442.photobucket.com/albums/q...dValley109.jpg

Here is a view from the 7 o’clock position.

http://i442.photobucket.com/albums/q...dValley090.jpg

Should I keep the tank plastic orange, or paint it black? If I keep the tank plastic orange, should I keep, or remove the lettering?

Spud :)

Boy, the sun didn't change much between four and seven o'clock. :wink:

Ditch the lettering and let's see how it looks. Don't paint the plastic yet.

:roll: :lol:
OK. I ditched the lettering. ;)

http://i442.photobucket.com/albums/q...dValley051.jpg

Spud :)

It looks great, Spud. Ride it!

The black tank plastic would appear somewhat similar to the retouched photograph shown below.

http://i442.photobucket.com/albums/q...dValley058.jpg

Spud :)

It's Your bike, If You like it, it's all good :D

Thank you for the suggestion to trim the rear side plastic, AZ! :) The Zong's rear end looks a lot slimmer after I trimmed it a bit. ;) :D

Spud :)

Thank you for the suggestion, WG. :) I ended up using a cutting wheel on a 4 ½” angle grinder to make the first, rough cuts. I made the final, precision cuts with a cutting wheel on my Dremel tool. :D

I am pleased with the results of my experiment. My YamaZong is now lighter, with less wind resistance than before. :)

Did someone also mention aftermarket fuel tanks as an option? Hmmmm… ;) :lol:

Spud :)