Zongshen 200GY-2 Tank Plastic Mod

[Cal25]

Maybe you could add a shim under the rear of the tank and perhaps the seat also to gain the needed clearance ?

First thought was to heat up the area on the tank that rubs, and mold it inwards just a bit. Not sure how logical that would be though.

[SpudRider]

Originally Posted by Weldangrind

No kidding! I couldn't sleep last night; I kept thinking about this tank thread!

I'm sorry about your sleepless night, WG!

Originally Posted by Weldangrind

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.

Originally Posted by Weldangrind

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

I will try to make amends by adding the Clarke fuel tank as an option in the poll.

Spud

[SpudRider]

Originally Posted by Cal25

Maybe you could add a shim under the rear of the tank and perhaps the seat also to gain the needed clearance ?

First thought was to heat up the area on the tank that rubs, and mold it inwards just a bit. Not sure how logical that would be though.

Thank you for the fine suggestion, Cal. My good friend Andy, who designed and fabricated my Yamaha XT225 lower shock mount, suggested something similar. I am going to confer with Andy this weekend. I have no doubt we can get the Clarke tank mounted solidly, without any contact with the engine. My only remaining question in regards to the Clarke fuel tank is the motorcycle's final appearance.

Spud

[Weldangrind]

Love it! Run that tank. The crowning touch is the "*Clarke* USA" script on the filler.

Regarding the side panel issue, I say meh. Nobody (including you) will see it when you're riding.

Figure out whether you need to space the tank, modify the tank, grind the aluminum or a bit of all three and enjoy the massive volume. Be careful though, there will be a considerable difference in the new center of gravity.

Your property is very clean.

[AZ200cc]

Use it, Minor mods, Fair looks....Why not?

[tconners]

what about using some heat to push in the tank where it rubs?
That whole tank is formed with heat.

[SpudRider]

Originally Posted by tconners

what about using some heat to push in the tank where it rubs?
That whole tank is formed with heat.

Thank you for the good advice. What is the best way to heat, and reshape the fuel tank, without damaging it? :?:

Spud

[fishman10]

cheap harbor freight heat gun and then some thing to push in slightly on the heated area,I think i got my heat gun for $9.00 ,It will work,!!!

[Weldangrind]

That seems reasonable, although judicious use of the heat gun is recommended. I guess it depends upon how much the tank cost, and if the rewards are worth the risk of creating a leak.

I was at HF today, and I can confirm the $9.00 heat gun.

[SpudRider]

Originally Posted by Weldangrind

That seems reasonable, although judicious use of the heat gun is recommended. I guess it depends upon how much the tank cost, and if the rewards are worth the risk of creating a leak...

Once again, you make a very good point, WG. The Clarke fuel tank costs $195, and I don’t wish to take any chances that I might compromise its structural integrity.

Yesterday I conferred with my good friend, and professional mechanic, Andy. We decided we could mount the Clarke fuel tank without altering either the fuel tank, or the engine block.

I am definitely going to mount the black Clarke fuel tank to my YamaZong. I will also be retouching the paint on my motorcycle’s plastic; therefore, I am considering alternate color schemes for my YamaZong with the Clarke tank. As DesertRider previously stated, “black goes with anything.” Therefore, I am considering the following options.

This retouched photograph represents my repainted Zong with the original KTM Orange.



Here is the Honda Red option.



How do you like Kawasaki Green?



I could also try Suzuki Yellow.



Finally, I am considering a patriotic blue color.



What do you think, gentlemen? Which color scheme do you like best?

Spud

[Weldangrind]

Orange first, blue second (much as Patriotic blue sounds great, I think it's Yamaha blue).

Why are you considering new colours? The orange looks great! That said, there is a certain poetic justice in choosing Yamaha blue.

[Cal25]

Yellow is my favorite color, but for some reason it does not look right to me. All the other colors look fine.

A few decals might look good also.

[SpudRider]

Originally Posted by Cal25

Yellow is my favorite color, but for some reason it does not look right to me. All the other colors look fine.

A few decals might look good also.

You have a good eye, Cal. I had the wrong shade of yellow in a couple spots. :oops: I have corrected the retouched photograph. Also, you might prefer the yellow Clarke fuel tank.



Spud

[SpudRider]

Originally Posted by Weldangrind

Orange first, blue second (much as Patriotic blue sounds great, I think it's Yamaha blue).

Why are you considering new colours? The orange looks great! That said, there is a certain poetic justice in choosing Yamaha blue.

After riding my Zong for 16,500 miles, the painted plastic is beginning to fade a bit. I have also been inspired by the beautiful paint job on DesertRider’s Zong.

I am presently partial to the KTM orange and Honda red. I certainly agree that choosing blue has poetic justice. I believe that Yamaha blue is a lighter shade than "patriotic" blue. When I repaint, I plan to use Krylon Fusion spray paint.

http://www.krylon.com/products/fusion_for_plastic/

I have read several good reports on this paint from both ATV and motorcycle owners. However, as DesertRider has attested, it is very important to properly prepare the plastic surface.

http://forum.highlifter.com/Krylon-F...-m1794457.aspx
http://forums.13x.com/showthread.php?t=138815
http://www.garagejournal.com/forum/showthread.php?t=984
http://www.kawasakimotorcycle.org/fo...on-fusion.html
http://www.exriders.com/vbb/showthre...hreadid=222242
http://www.break.com/usercontent/200...ic-699436.html

The Krylon Fusion colors appear to match the motorcycle manufacturer colors very well, except for Yamaha; the closest blue I can find is the “patriotic blue.”

Spud

[Weldangrind]

Originally Posted by SpudRider

After riding my Zong for 16,500 miles, the painted plastic is beginning to fade a bit.

I presume that the existing colour is not a painted finish, so can you do anything to brighten up the colour? I bought an old Suzuki a few years ago that suffered from a horrible spray bomb job, and the colour was an awful dijon mustard. I spent considerable time wet sanding the colour off (because I couldn't find a chemical that would strip it), and it looked great. I followed with some clear silicone spray to protect it and give it some shine, and it worked well. It's really easy to keep the surface clean now.

Maybe you could clean the plastic, use a clay bar to remove contaminants and then wax it. Couldn't hurt. :wink: