Lou_zx12r
Expert Class
One Day at a Time
Posts: 196
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posted June 19, 2007 04:14 AM
gas leaking from overflow tube
long story short, rode the bike this past weekend to Laconia. first real ride for this year. upon my return the next morning i found a puddle under the bike, gas. for some reason gas flows out the overflow tube. The bike is a 2000 and I had the recall done over 2 yrs ago. gas gauge sending unit and I believe there was another recall for a weight on some tube inside the gas tank (not sure exactly). Does anyone know what would cause the gas to flow out the overflow besides too much gas and being parked in the sun as to cause expansion? This happens just sitting there doing nothing.
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2000 ZX12R 40shot
2012 ZX14R
2009 Concours 14
  
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Texas12R
Zone Head
Posts: 545
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posted June 19, 2007 05:10 AM
I reserve the right to be wrong.....I do that quite well!
If the tank has no vent it might push fuel out with expansion.....?
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Lou_zx12r
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posted June 19, 2007 07:04 AM
I thought of that, but the gas leaks out when just sitting there even with the gas cap opened. Does anyone know if there is a valve inside for the overflow? Maybe the valve is malfunctioning or something.
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2000 ZX12R 40shot
2012 ZX14R
2009 Concours 14
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entropy
Moderator
Posts: 8671
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posted June 19, 2007 08:57 AM
quote:
I thought of that, but the gas leaks out when just sitting there even with the gas cap opened. Does anyone know if there is a valve inside for the overflow? Maybe the valve is malfunctioning or something.
That's the same thing mine did before i took it in to be fixed.
I was told there was a crack in the overflow tube where it was attached to the tank(inside the tank) so gas could leak from inside the tank into the overflow tube and then down onto the ground.
Its been 6 years so i might not remember it correctly, but a new tank fixed it.
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VincentHill
Needs a life
Posts: 6520
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posted June 19, 2007 09:23 AM
I posted everything about this and now see it did not post! (I was even first  )
First see if the place it is leaking from is the tube on the left front of the tank!
If it is, then remove the tank, drain it and remove the Fuel Pump. Run your hand inside the tank (Unless you are a huge guy it should fit) and find the crack or break in the line.
Take a set of Side cutters and cut out a 2 inch section. Get the best rubber tubing you can find to ft that (Fuel Injection Grade) and cut off a 4 inch section and using to hose clamps slide this hose over both ends of the 2 tubes and using a short stubby screw driver tighten the clamps.
Put the Fuel pump back in and you are in business.
WHen I made my low cut tank, I got a tank that had this problem and saw the broken line. The old cure was to clamp on a weight to change the frequency of the vibration to keep the line from cracking.
This line is the water drain from the top of the tank. Worse case, you could solder the top hole and bottom tube and be done with it. (Of course you would have to be careful in opening the tank after a rain!
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Made History @ Daytona and still one fast old man!!
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Lou_zx12r
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Posts: 196
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posted June 20, 2007 04:51 AM
Vincent, thanks for the info i appreciate it and now have something to do this Saturday. A couple of question though
1. will the clamps cause rust in the tank? should i replace the tube & clamps every year if i fix this
2. do all year 12's use the same tank, if os i may start looking for a later model tank
3. do the later model tanks have the same issue or just 1st gen 12's
thanks in advance 
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2000 ZX12R 40shot
2012 ZX14R
2009 Concours 14
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VincentHill
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posted June 20, 2007 05:41 AM
Hose Clamps are Made from Stainless Steel #1 and #2, the inside of your fuel tank is untreated steel! The reason is Gasoline is made from "OIL" and still has "OIL" in it which is why they say keep your tank full when sitting to keep it from!! Rusting.
I use the hose and clamps in my Land SPeed Racer and I did this several years ago and it is fine.
#2, when you take out your fuel pump you will see that they use rubber hose and clamps and that lasts for 5 , 10 Years (Who Knows)? DId you plan to change the Fuel Pump hoses in you van or car every year? (Now do you feel safe?)
Yes they are all the same tanks fittings.
Last, either they installed the fix on all of the later tanks or they changed it but I have not heard of any new problems!
Nothing too difficult, you will be fine even with limited knowledge! What if you Mess up totally?? Are you any worse off??
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Lou_zx12r
Expert Class
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Posts: 196
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posted June 20, 2007 09:25 AM
Vincent guess I didn't look at it as closely as you did. Thanks for enlighting me. Ok so I should be all set than to perform the fix this weekend. Thanks for taking the time to respond and increasing my knowledge of things I do appreciate it..
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2000 ZX12R 40shot
2012 ZX14R
2009 Concours 14
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buddy
Expert Class
Posts: 335
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posted June 20, 2007 10:05 AM
I don't think all the tanks are the same. I have an 01 and I have available an 05 fuel pump. It won't go into the opening for the 01 fuel pump.
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VincentHill
Needs a life
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posted June 20, 2007 10:26 AM
quote:
I don't think all the tanks are the same. I have an 01 and I have available an 05 fuel pump. It won't go into the opening for the 01 fuel pump.
Thanks Buddy, I Know the Fuel Pumps and return line set up are different on the 02 and later but did not know that they changed the plate.
After cutting a few tanks apart and having everything out of mine a few times, you end up knowing a lot more than you ever needed! I understood what you were getting at (The Longevety of the repair and probelms associated with it) which was the reason I mentioned the fuel pump and all of the rubber hoses it has sitting 24 / 7 in the fuel and the fact that the tanks are plain stamped steel and at least the Hose clamps are SS
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Made History @ Daytona and still one fast old man!!
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