HI all\\

I just picked up my 2006 zx14 with only 8k on it for a steal...at least I thought it was. It wasn't leaking when I picked it up with almost no fuel in it. As soon as I filled it and started it up, fuel started pooring out the overflow tube. If I shut it off, it still leaks.

Can I plug it temporarily? I can't get an appointment at the dealer until next week?

Any ideas?

* Last updated by: Eastcoastmod on 3/22/2012 @ 7:59 PM *

How far did you fill it to in the tank?I wouldn't go plugging anything just yet....not until you figure out what's creating that pressure while running.I would say....the engine is heating an already full tank...'overfilled' it sounds like...and causing that.BUT...it would be doing it at shutdown as well...probably moreso.You can look on top of the engine there by the valve cover...anywhere along there...is there a RUBBER 'blanket' covering the engine top?(with holes for the plugs and such naturally).

At least you know your overflow tube is clear...that's one good thing...seriously.It's not running down on your pipes is it? If it is..ya gotta stop that IMMEDIATELY ya know.Reroute that tube if it is.

Is it a California Model?Maybe call the owner and ask him what's up?I would.

* Last updated by: Grn14 on 3/22/2012 @ 3:56 PM *

I checked it again tonight. Once the fuel is down to the last bar, it stops. I went for fuel and only put in 7 litres when I started to see it dripping. The bike was off. Started the bike and it continued to leak. Went for a ride. Continued to leak while riding. RPM didn't seem to affect it. Stopped and turned the bike off, continued to leak. I tried folding over the end of the tube and closed it off with a zip tie. At first...no leak. After a couple of minutes idling gas started pooring out from the bottom left of the tank. I couldn't tell exactly where it came from but it was leaking pretty bad.

Unfortunaly this was an auction purchase with basically no recourse.I'm SOL no matter what the problem is.

I have read a few posts that suggest the hose may have come loose inside the tank. Is there a hose inside the tank? I couldn't see one. I have also read that on many zx12s the overflow nipple somehow cracks allowing fuel to pass from the inner to outer tank.

I have already removed the tank to examine it. Everything looks fine but I really don't know what to check for. the bike only has 12000 kms on it and looks imaculate. It was clearly properly stored and babied.

Any other tips before I have to take it to the dealer next week where they are known to gouge people?

Thanks in advance.

Honestly can't think of anything else it could be.Sounds pretty dangerous to me however.I don't think I'd be doing any riding with it like that(except to your Dealer).Geez...you don't want to flame yer new bike there!

It's an 06...so very possibly the tubing is rotted somewhere?Even if she just sat or whatever.

* Last updated by: Grn14 on 3/22/2012 @ 8:13 PM *

If I am not mistaken, the only way fuel can get to the overflow tube is through the hole up at the top of the filler neck. It should not be able to overflow unless fuel is at the tippy top---and then some. There has to be some kind of pressure that is pushing fuel out on an almost empty tank. Seems like the same effect as propellant in a spray can.

Just speculating here--if this is a Cali bike, could it have blockage in the evaporative emissions system? Vapor is the only thing that I can think of that would cause pressure in the tank.

Ya...that's what I was wondering also Rook...the Calif fuel evap canister thing.An 06....IF she's a Cali model....that canister may be totally shot and non-functional by now.It doesn't have that many miles on it...so if it was gummed up...you might never think of it.

I guess you COULD try opening the fuel door next time she starts dripping.See if that has any effect on it dripping?If so...you definitely have a pressure buildup going on somewhere...not okay.I would open it SLOWLY however...if you're getting fuel up around that overflow...you don't want it blasting out on your bike there.

Did you check to see if the engine rubber blanket(hot wind cover) was on there?

* Last updated by: Grn14 on 3/22/2012 @ 8:44 PM *

There is a tube inside the tank that leads from the overflow inlet in the cap area to the outlet tube where the rubber hose attaches. Sounds like the metal tube inside the tank has somehow developed a leak and when the fuel level gets below that point, the leaking stops.

thanks for the info guys.

This is a Canadian model so I don't think is has the Cali smog gear on it. Plus It starts leaking when it gets around 7 litres of fuel in the tank so I don't think it has anything to do with the top of the tank. I put some fuel in it last night and parked it with a drip can. When I woke up, I was down to one bar for fuel so it basically drained out. Where is this metal tube located inside the tank? Is there any way to access it? Is it possible that the tank somehow split on the inside? If the bike was in rough shape I could understand but this one looks mint. there is no corrosion on it anywhere and shows no signs of poor storage.

Thanks for all the help. I will let you know what it turns out to be.

Colin

Remove the seat. How many tubes are coming out of the end of the tank? 2? He sold well. I'd buy from him again. It needs a tank. You pull the pump or the float assembly, it will be wise to change those out as per manual. They tend to leak when the original seal is broken.

When you look up inside the tank, you can stab a tube, see if it has integrity or it moves. The meguyveer fix:

1. Take a tube, run it up past the level of the tank filler cap. This stops the flow out with a full tank.
2. Problem #2. Imagine you hit the brakes. Imagine you accel with a full tank. That tube's end is open needing a vent for the tank. There is enough slosh to move the fuel out of the tube.
3. Problem solved. Take one of those hand pump handles apart. This has a one way ball so you can suck air and now wind up the handle part over the tube. If the slosh comes, the ball locks up the rush of fluid. Back drops the ball = The air vent kicks back in. Meguyveer jerryrigs it home.
4. Year Fucked!

I only have one nipple at the rear of the tank which has the drain tube connected to it. I just looked at the schematic for the tank. It shows a solid tube running inside the tank from that nipple to the drain hole in the filler assembly. It appears its only purpose is to drain spillage or water if the gas cap leaks when it rains. The kawi dealer just suggested I plug the nipple and fill er up. I am hopeful :)

The tube in the tank cannot be purchased according to kawi.

* Last updated by: Eastcoastmod on 3/23/2012 @ 8:22 AM *

Something doesn't sound quite right here.Shouldn't there be a vent tube to prevent the tank from overexpanding or compressing?Is this the same tube as the 'overflow' deal?If it is...WHY would fuel be going into and out of that tube?You say it begins to leak at 7 ltr.WHY would it be doing that?Something isn't right.Plugging that tube end may be very dangerous if you're somehow getting a pressure build-up in there...why it would do that....IDK.

* Last updated by: Grn14 on 3/23/2012 @ 8:55 AM *

I only have one nipple at the rear of the tank which has the drain tube connected to it.

There has to be two nipples unless the tank was modified. Three nips if it was a Cali model. If the breather was cut off and welded shut, that would certainly cause a lot of pressure in the tank when the fuel and vapors got warmed up. the fuel might get pushed out of the overflow like an aerosol can when the air in the tank warms up from the engine heat. I would say it is quite unsafe to operate the bike like that. The tank is emmitting fuel so that it does not explode. Both pretty dangerous scenarios.

Shouldn't there be a vent tube to prevent the tank from overexpanding or compressing?

WHY would fuel be going into and out of that tube?You say it begins to leak at 7 ltr.WHY would it be doing that?

Sounds like the metal tube inside the tank has somehow developed a leak and when the fuel level gets below that point, the leaking stops.

maybe? Seems doubtful that the tube would be leaking internally---but another possibility. I either case, you prolly need a new fuel tank. no welder is going to repair a fuel tank....

On a ZRX Kawasaki there is an overflow tube inside the tank that goes from the gas cap to the bottom of the tank. It is there for if gas expands it will go out the over flow and not out the cap and on the out side of the tank. These tubes some times ctack or break then gas comes out of the over flow and on the ground if you are lucky. It will stop when it gets below the breake or crack in the tube.
KwiK fix is to plug the oever flow at the bottom of the tank and not top off the tank on a fill up or the gas expansion will go past the cap and stain the tank paint.
At least with the 14 you might be able to see the tube when you pull the fuel pump.

Just a thought

Okay, hold on here. Never heard of one tank nipple out the back of a tank, but I have seen 3 and 2. So now we are down to 1 and that WAS for the water drain (((under the filler cap))). Then, that explains it. Here is the problem. Yes, technically you need a new tank. No, you do not need one if you keep an eye on the rubber cracking. If using a plug or whatever you use, make sure it is marine grade.

So, the tube did drop down some. It starts leaking at whatever height that a 1 bar reads. The next thing is to plug the weather drain or you drop all that crap down into the tank, clog the filter, let alone start sucking water, you don't address that now. Be caught in an unexpected rain? Water is heavier than gas. You'll stop running within a few hundred yards you are caught in a downpour.

Update

I plugged the nipple and filled her up. Waited and watched....no leak. :)
Started the bike....waited....no leak :)

Drove the bike a few hundred metres and looked down at fuel comming out around the gas cap.
Shut the bike down and openned gas gap....fuel had been sucked through that drain tube up into the top of the tank.

I can only assume now that the vaccum created in the tank is now sucking the fuel up the broken drain tube into the top of the tank.

If I plug that drain hole at the top of the tank will the vaccum created when running cause any issues?
I don't think it will but I would like a second opinion.

Thanks again :()

YOu pop the cap to see if that funnel type nipple is sticking out of there? That should be the vent for the tank. That is the only other place I can think of? Either you starve for gas or the tank implodes.

I can only assume now that the vacuum created in the tank is now sucking the fuel up the broken drain tube into the top of the tank.

Take a golf T and lightly push it in so it won't come out. Take it for a ride so it does not slosh up. I think your gas cap vent is the obvious vent, unless I get snagged again?

."fuel had been sucked through that drain tube up into the top of the tank".....how does fuel get sucked up into the drain tube and into the top of the tank?The drain tube(vent)is not in contact with fuel.It can only allow fuel to come into it by overflow.Nah....something isn't cool here.One tube?No....not okay.Take a look where your nipples are welded to the rear of the tank there.Does it look like someone MAY have sealed a tube there,maybe ground it down and plugged it,then sanded and painted over it?(WHY anyone would do that is beyond me)...BUT...stranger things have happened.

If the tank is compressing...the tube would pull air...not gas...and it wouldn't end up leaking.If the tank was expanding,it MAY get some fuel in there from the top of the filler neck(most likely only when full up),but that would be very noticeable IF you tried to open the cap.It would blast open pretty well.Do you get ANY whistling through the cap when she's just been ridden and filled?Or any whistling at all through the cap..like sitting in the Sun or hot engine just sitting there..

IF the only tube you have there is dripping fuel...and that JUST HAPPENS to be the vent tube...plugging that will be extremely risky...gotta tell ya...I wouldn't go plugging ANYTHING.You shouldn't HAVE to...period.I still think you've got a California model...somehow...it just sounds too strange to me.Maybe the guy thought he could 'bypass' the Cali Evap stuff...ended up getting it wrong somehow?

C'mon Hub...figure this out.Geez..it can't be TOO difficult....There's only either two lines...or three,depending on the state she's from.

It has to have TWO at least...stock...from the factory.Anything less...nope....not factory.Or modded for some reason.Ditch the tank my friend...before ya get killed.

* Last updated by: Grn14 on 3/23/2012 @ 11:47 AM *

Drove the bike a few hundred metres and looked down at fuel comming out around the gas cap.
Shut the bike down and openned gas gap....fuel had been sucked through that drain tube up into the top of the tank.

No it was just pushed up the from the pressure caused in the tank after the vapor and fuel heated up and expanded and had nowhere to go.

Quite screwing with this before you kill yourself. $500 get a new tank.

Bout time!!!!LOL!!!

* Last updated by: Grn14 on 3/23/2012 @ 11:55 AM *

In the mean time don't fill the tank because the gas (as I said before) can only go out the cap from expansion.

Last update.

I put the bike in the sun. Openned and closed the gas cap....waited 2 minutes and openned the cap again. The top of the tank was almost completely filled with fuel. So yes something is plugged. Maibe in Canada we have the Cali smog gear. Not sure yet. I inserted a nylon screw into the drain hole and closed her up. Waited a bit....and didn't get any fuel up there. Started the bike and ran it for awhile. Openned the gas cap again but only heard the normal presure realease you would expect to hear. I took it for a ride. I can't feal any starvation happening.

there you have it...a temporary fix so I can enjoy the bike until my appointment next Thursday. Our riding season here is very short. This time of year the temps are usually around 0 celcius. Since we have good riding weather now, I'm going to enjoy it.

Thanks again

I put the bike in the sun. Openned and closed the gas cap....waited 2 minutes and openned the cap again. The top of the tank was almost completely filled with fuel.

That is because the hot sun is enough to make expansion pressure release from the tank. I have heard mine on a hot summer day. Everyone has heard this. Your's is not releasing so that is why you have fuel getting pushed up to the top but nowhere to go.

heard the normal presure realease you would expect to hear.

be careful ECM.

Okay...well..now you know at least that the venting/overflow tube is pinched or something.Good news.Like Rook said though...Be Careful.Expansion of vapors and such could be a disaster if it has nowhere to go.I have on occasion opened my cap for whatever reason...like when it was hot or something just to check it out...and I've had some pressure(minimal) escape as I cracked it open....even with a good fuel vent.It should whistle though...most of em do when they're at a point of expansion...even with that tube.Hot Sun...hot engine.

Kinda weird though that she would whistle...even with the vent clear????IDK...mine has anyway.My 07 used to do all the time.My 2012...a couple short ones so far.Probably be whistlin 'Dixie' come Summer

Whistling=good.Tank sides bulging out=bad.

What's really strange with yours...fuel in the filler top area.That doesn't make sense.That's a lot of vapor expansion if that's what's doing it.Did you check the engine hot wind seal yet?You didn't say...so I was just wondering.IDK IF that could maybe play a part in all this...since the Airbox is in between...but....It's there for a reason.

* Last updated by: Grn14 on 3/23/2012 @ 3:26 PM *

I drove the bike for an hour without any issues. I am positive the metal drain tube in the tank is broken or cracked. There is no play in it what so ever so I don't think it came unhooked. The heat expansion simply pushed the fuel up and out of the tube and pretty much filled up around the filler. No that it's plugged I have no issues but still need to get it fixed properly. If that drain tube wasn't broken, where would that pressure get released to in a properly working bike?

I'm taking a break from it until Sunday.