Easy Method for Installing the Fuel Tank Shrouds

[SpudRider]

Replacing the fuel tank shrouds can be a frustrating experience. Here is the method I use to make this process simpler.

1) After replacing the fuel tank, try starting the engine. If the engine won't start because you kinked the fuel hose, et cetera, you can remedy the problem before you put together all the plastic.

2) After you have verified the engine will start, place one of the fuel tank shrouds behind the upper engine guard.

3) Standing at the front of the bike, use your inboard hand to start the bolt which connects the tank shroud to the radiator strap. Tighten this bolt by hand for only a few threads. You want this bolt to remain in place, but you want it to remain loose, allowing movement of the shroud.

4) Place the top tank bolt into the shroud to hold the shroud in position. Also keep this bolt loose.

5) Flexing the shroud forward, tighten the phillps screw near the headlight. If you wish, you don't need to replace the second phillips screw under the beak. The headlight screw is enough to hold the front of the shroud securely.

6) Place the remaining bolts into position, but don't tighten them.

7) Tighten the bolt which attaches to the radiator strap.

8) Tighten the rest of the bolts.

Repeat these steps for the second, fuel tank shroud.

[SpudRider]

I have added this thread to the RX3 Tech Sticky, under the Maintenance subheading.

http://www.chinariders.net/showthread.php?t=14228

[keithmaine]

Love all the tips I can get

[jbfla]

Spud, you must have been reading my mind.

But where are the pictures?

I think I mixed up a couple of bolts.

Are the 2 bolts with the large washers the ones that go on the inside of the panel (radiator)?

And what is the name of the piece on the right? It goes inside the rubber grommet. One of mine was missing...I'm pretty sure I wasn't responsible...

Edit: I looked at a photo I took of all the parts I removed and.... there are 2 of the parts on the right in the photo... and ...I can't find a replacement at the local hardware store.





jb

[SpudRider]

Originally Posted by jbfla

...I think I mixed up a couple of bolts.

Are the 2 bolts with the large washers the ones that go on the inside of the panel (radiator)?...

Yes.

Originally Posted by jbfla

...And what is the name of the piece on the right? It goes inside the rubber grommet. One of mine was missing...I'm pretty sure I wasn't responsible...

Edit: I looked at a photo I took of all the parts I removed and.... there are 2 of the parts on the right in the photo... and ...I can't find a replacement at the local hardware store.

That part is called a bushing washer. You can order them from CSC. I suggest you order a couple, in case you misplace one in the future. Until the replacement part arrives, you can use a regular washer.

[SpudRider]

Originally Posted by keithmaine

Love all the tips I can get

You're welcome. Thank you for the kind words of encouragement.

[woodlandsprite]

Wish I had had this reference when I was putting the bike back together those shrouds were surprisingly fussy to get back on!

[rjmorel]

Amen and thank you Spuds for telling us another more better way of Zonging. rj

[RedHawk47]

Thanks for restoring my sanity. I had adjusted my valves and was having TROUBLE putting the second shroud on. I had put the rear bolt in, and the top one in the tank and found this:

There was no way that screw was going in. I remembered this post, but, how was I going to find it - what to search for? I took a break for dinner and finally the light bulb came on: Sticky...Maintenance. Eureka!!

I read the instructions and said to myself "I don't know how this will help, it is so far off." But I did it and it worked.
Thanks.

[SpudRider]

You're welcome, Dan.

People should always check the sticky threads at the top of this forum, especially the Zongshen RX3 (ZS250GY-3) Modifications & Maintenance thread.

http://www.chinariders.net/showthread.php?t=14228

[willy dog]

that one under the beak is tough, one side no problems the other i just left out for my sanity

[SpudRider]

Originally Posted by willy dog

that one under the beak is tough, one side no problems the other i just left out for my sanity

I don't bother to install either of those screws. They are not necessary. They will only drive you crazy.

[Juanro]

Having taken it apart and assembled it again many times with moderate success (no pieces fell afterward and no unexplained remaining screws) I use a method similar to that described by our fellow Spud... but I put the front, under the beak screw first. Then everything else as stated.