Fuel Tank leak

qwert · 10-30-2015, 12:39 PM

Firstly sorry to anyone who has noticed my relentless questions and lack of contribution. I've had my Zong only a few weeks and it's a steep learning curve for me. I can only promise some great photos once shes running as she should be.

So todays problem...I've noticed a very strong smell of petrol in my garage, finally decided that it'ls too strong to be normal. I removed the fuel tank securing bolt and lifted it up slightly. Sure enough there is an ever so slow but regular drip of fuel from the rear left handside corner underneath the tank. Its hard to tell if the fuel is leaking from here or if its running here from somewhere else. All the connectors look ok.

Could anyone give any advice where to start looking for the source? What it the best way to remove the tank/fuel?
Thanks again!

rtking · 10-30-2015, 12:51 PM

Hi Qwert,

Best bet is to invert the tank and look at the connections. You have two quick-connects for the fuel pump/fuel filter which lock with a positive click, then there are two rubber hose connections that are just pushed into a barbed nipple. Lastly, there's the fuel level sender which has its own gasket.

Start by wrapping the top of the tank in a towel or bubble wrap (to prevent scratches), and put a rubber mat or towel on top of the frame behind the fuel tank. You'll pull back on the tank and turn on its side. You won't get too far due to two electrical connections for the fuel level sender and fuel pump. Undo those connections and you should have enough hose length to invert the tank and check the rubber hose connections.

My guess is that one of the pressed on rubber hoses has come loose. Double check those hoses for cracks and, if none found, you can use a plastic zip-tie to secure the hose on the barbed nipple. While there, double check your fuel injection lines by squeezing both tabs on each of the lines and wiggling back. Once free, make sure the area is clean before re-attaching the hoses.

Hope that helps to identify and cure the leak!

rtking · 10-30-2015, 12:51 PM

BTW, questions are good as we are all learning!

detours · 10-30-2015, 12:56 PM

This tutorial on valve adjustments will show you how to remove the fuel tank with pics. Basically you remove the seat, side panels and then tank.

http://www.cscmotorcycles.com/Articles.asp?ID=267

qwert · 10-30-2015, 01:23 PM

Great stuff guys thanks. I'll try tomorrow. If I'm inverting the tank does it need to be empty or will it stay sealed? I had a thought thst it's dripping from the rear left side as thst where it would naturally go with bike on its side stand, even if it's leaking from a different location. I'll keep you updated!

SpudRider · 10-30-2015, 02:00 PM

As usual, these guys gave you excellent advice.

After you turn the fuel tank on its side, if the tank is near full, it is likely to drip a little petrol from the cap. If the fuel lines are not fully snapped onto the fuel pump or fuel filter, they will also leak some fuel, until you press the lines fully into position. In short, be prepared to spill a little more fuel, until you find the leak.

qwert · 10-31-2015, 04:21 PM

Ok, so followed your advice. Got the tank inverted and had a good look. One connector was a bit loose but dry and definitely not leaking. I cleaned and dried the underside then sat and waited.... Slowly a drop formed on the bottom edge of the tank. Upon closer inspection fuel seems to be seeping out from underneath the fuel tank next to where the main retaining bolt goes. Specifically from under some kind of strengthing plate underneath. Very slow but definitely a leak. Anyone e any ideas? I see CSC has tanks in Stock so I may just go ahead and order one. Thanks again for help

rtking · 10-31-2015, 04:24 PM

Quote:

Originally Posted by qwert

Ok, so followed your advice. Got the tank inverted and had a good look. One connector was a bit loose but dry and definitely not leaking. I cleaned and dried the underside then sat and waited.... Slowly a drop formed on the bottom edge of the tank. Upon closer inspection fuel seems to be seeping out from underneath the fuel tank next to where the main retaining bolt goes. Specifically from under some kind of strengthing plate underneath. Very slow but definitely a leak. Anyone e any ideas? I see CSC has tanks in Stock so I may just go ahead and order one. Thanks again for help

That sounds like a crack in the tank as there isn't any connections there. Give them a call today, I think they're there until 5:00 pacific. Maybe they can help and send a replacement under warranty?

SpudRider · 11-01-2015, 01:39 AM

Quote:

Originally Posted by rtking

That sounds like a crack in the tank as there isn't any connections there. Give them a call today, I think they're there until 5:00 pacific. Maybe they can help and send a replacement under warranty?

That gentleman is in the United Kingdom.

Since he doesn't list his location, I made the same mistake as you, until he made a reference to Katflap.

rtking · 11-01-2015, 01:44 AM

Quote:

Originally Posted by SpudRider

That gentleman is in the United Kingdom.

Since he doesn't list his location, I made the same mistake as you, until he made a reference to Katflap.

Ah! Thanks Spud, and apologies to Qwert.

I wonder, if there is indeed a crack, this could be repaired by welding?

Weldangrind · 10-31-2015, 07:52 PM

Quote:

Originally Posted by qwert

Ok, so followed your advice. Got the tank inverted and had a good look. One connector was a bit loose but dry and definitely not leaking. I cleaned and dried the underside then sat and waited.... Slowly a drop formed on the bottom edge of the tank. Upon closer inspection fuel seems to be seeping out from underneath the fuel tank next to where the main retaining bolt goes. Specifically from under some kind of strengthing plate underneath. Very slow but definitely a leak. Anyone e any ideas? I see CSC has tanks in Stock so I may just go ahead and order one. Thanks again for help

Can you show us a picture? I'm very curious.

SpudRider · 11-01-2015, 10:53 AM

Yes, if you remove the bolts you can carefully withdraw the fuel pump from the tank. Do you have a leak coming from the fuel pump gasket? If so, you will definitely need to replace the gasket when you re-install the fuel pump. If it isn't leaking from this area, I wouldn't remove the fuel pump.

You can purchase a new fuel tank from Taobao, in any of the standard colors.

https://item.taobao.com/item.htm?spm...cket=10#detail

https://item.taobao.com/item.htm?spm...cket=10#detail

https://item.taobao.com/item.htm?spm...cket=10#detail

https://detail.tmall.com/item.htm?sp...=1&abbucket=10

qwert · 11-01-2015, 01:00 PM

Warranty is not an option. I'm the second owner of the bike in the UK. The warranty is still valid, however I'd need to take it to a certain shop which is pretty far away. I will enquire if anything can be done by mail but I'd like to progress while I await an answer.

Spudrider, thanks for all your knowledge and help! Regarding the fuel pump, there are no leaks from the gaskets or bolts. My thinking is if I order a new tank then it's just the tank... I remove all the connecters on my current tank and fit them to the new one. Is it not as simple as this?

qwert · 11-01-2015, 01:02 PM

Spud would you possibly have a link in blue please?

SpudRider · 11-01-2015, 04:36 PM

Quote:

Originally Posted by qwert

Spud would you possibly have a link in blue please?

I'll look.

In the meanwhile, I suggest you read the following thread which describes how to order items from Taobao.

http://www.chinariders.net/showthread.php?t=14466

10-30-2015, 12:39 PM	#1
qwert Join Date: Oct 2015 Location: UK Posts: 17	Fuel Tank leak Firstly sorry to anyone who has noticed my relentless questions and lack of contribution. I've had my Zong only a few weeks and it's a steep learning curve for me. I can only promise some great photos once shes running as she should be. So todays problem...I've noticed a very strong smell of petrol in my garage, finally decided that it'ls too strong to be normal. I removed the fuel tank securing bolt and lifted it up slightly. Sure enough there is an ever so slow but regular drip of fuel from the rear left handside corner underneath the tank. Its hard to tell if the fuel is leaking from here or if its running here from somewhere else. All the connectors look ok. Could anyone give any advice where to start looking for the source? What it the best way to remove the tank/fuel? Thanks again!
	0

10-30-2015, 12:51 PM	#2
rtking Join Date: Sep 2014 Location: Orange County, CA Posts: 410	Hi Qwert, Best bet is to invert the tank and look at the connections. You have two quick-connects for the fuel pump/fuel filter which lock with a positive click, then there are two rubber hose connections that are just pushed into a barbed nipple. Lastly, there's the fuel level sender which has its own gasket. Start by wrapping the top of the tank in a towel or bubble wrap (to prevent scratches), and put a rubber mat or towel on top of the frame behind the fuel tank. You'll pull back on the tank and turn on its side. You won't get too far due to two electrical connections for the fuel level sender and fuel pump. Undo those connections and you should have enough hose length to invert the tank and check the rubber hose connections. My guess is that one of the pressed on rubber hoses has come loose. Double check those hoses for cracks and, if none found, you can use a plastic zip-tie to secure the hose on the barbed nipple. While there, double check your fuel injection lines by squeezing both tabs on each of the lines and wiggling back. Once free, make sure the area is clean before re-attaching the hoses. Hope that helps to identify and cure the leak! Last edited by rtking; 10-30-2015 at 02:44 PM.
	0

10-30-2015, 12:56 PM	#4
detours Join Date: Sep 2014 Location: Arvada, CO Posts: 1,004	This tutorial on valve adjustments will show you how to remove the fuel tank with pics. Basically you remove the seat, side panels and then tank. http://www.cscmotorcycles.com/Articles.asp?ID=267 __________________ Red 5 standing by! 2015 CSC red RX3 with 19" front wheel, Shinko 804/805, skid plate, tall seat, 13T/45T sprockets, progressive shock, Winyoochanok windshield, GENSSI LED headlight, SW-Motech tankbag, Shorai Lithium battery 2014 Ural Patrol
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10-30-2015, 02:00 PM	#6
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	As usual, these guys gave you excellent advice. After you turn the fuel tank on its side, if the tank is near full, it is likely to drip a little petrol from the cap. If the fuel lines are not fully snapped onto the fuel pump or fuel filter, they will also leak some fuel, until you press the lines fully into position. In short, be prepared to spill a little more fuel, until you find the leak. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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11-01-2015, 10:53 AM	#12
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Yes, if you remove the bolts you can carefully withdraw the fuel pump from the tank. Do you have a leak coming from the fuel pump gasket? If so, you will definitely need to replace the gasket when you re-install the fuel pump. If it isn't leaking from this area, I wouldn't remove the fuel pump. You can purchase a new fuel tank from Taobao, in any of the standard colors. https://item.taobao.com/item.htm?spm...cket=10#detail https://item.taobao.com/item.htm?spm...cket=10#detail https://item.taobao.com/item.htm?spm...cket=10#detail https://detail.tmall.com/item.htm?sp...=1&abbucket=10 __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

10-30-2015, 01:23 PM	#5
qwert Join Date: Oct 2015 Location: UK Posts: 17	Great stuff guys thanks. I'll try tomorrow. If I'm inverting the tank does it need to be empty or will it stay sealed? I had a thought thst it's dripping from the rear left side as thst where it would naturally go with bike on its side stand, even if it's leaking from a different location. I'll keep you updated!
	0

10-31-2015, 04:21 PM	#7
qwert Join Date: Oct 2015 Location: UK Posts: 17	Ok, so followed your advice. Got the tank inverted and had a good look. One connector was a bit loose but dry and definitely not leaking. I cleaned and dried the underside then sat and waited.... Slowly a drop formed on the bottom edge of the tank. Upon closer inspection fuel seems to be seeping out from underneath the fuel tank next to where the main retaining bolt goes. Specifically from under some kind of strengthing plate underneath. Very slow but definitely a leak. Anyone e any ideas? I see CSC has tanks in Stock so I may just go ahead and order one. Thanks again for help
	0

11-01-2015, 01:00 PM	#13
qwert Join Date: Oct 2015 Location: UK Posts: 17	Warranty is not an option. I'm the second owner of the bike in the UK. The warranty is still valid, however I'd need to take it to a certain shop which is pretty far away. I will enquire if anything can be done by mail but I'd like to progress while I await an answer. Spudrider, thanks for all your knowledge and help! Regarding the fuel pump, there are no leaks from the gaskets or bolts. My thinking is if I order a new tank then it's just the tank... I remove all the connecters on my current tank and fit them to the new one. Is it not as simple as this?
	0

11-01-2015, 01:02 PM	#14
qwert Join Date: Oct 2015 Location: UK Posts: 17	Spud would you possibly have a link in blue please?
	0