zl1000 tank fixes?

[paulfun]

Ok we all know the zl1 tanks leak!~
what I am curious about is what all the fixes that have been used to seal the leaks at the front mounts.

After taking mine for a 12 mile test run I found one of the fixed tanks (not by me) was leaking on the fixed side as well as the other and will need fixed again

[KawTipper]

Ok we all know the zl1 tanks leak!~
what I am curious about is what all the fixes that have been used to seal the leaks at the front mounts.

I've had good luck using JB-Weld. getting down to bare metal and thoroughly cleaning it seems to be key. Attempting a fix at the mounts might be tough since there is some pressure and vibration at those points.

[Jarney]

Hey Paul, after getting my 1000 tank off the bike to clean the inside, I noticed mine was repaired as well at both front mounts. Turns out, whoever did it, did a poor job painting it to begin with, and the repair on the front mounts looks like crap - thank goodness it's on the bottom and can't be seen and doesn't seem to leak - for now. Since the repair was painted, I have no idea what they used - gobs of something - I'm thinking it's probably jb weld too. If I repaint the tank, I'll be removing that crap and doing a better repair. I think Kawtipper is right - needs to be welded/brazed/down to bare metal, etc., for it to be done right. Let us know what you wind up doing. Later.

[paulfun]

I am planning on having a GOOD welder (not Me) fix my other tank and then have it repainted before installing it. Problem is I would like to run it for a while and not have to let her sit any longer, so a quick fix on this tank that wont fall apart in a few weeks would be nice.
As you said its a stress point and I am not sure if my seal all will work due to the stress it will get.

My plan for welding is to remove the mount compleetly and add an a flat piece of steel then reweld the mount back in place. that should give it much better support.

[markus56]

Just in case there's someone out there that doesn't know one of the reasons why these mounts break in the first place......the tank rubbers have to be turned a certain way! If they are installed with the thick part of the tank rubber towards the frame......that's wrong!! To put them on like that would put those mounts in a serious bind so be sure to be watch that little tid bit as the ZL1k tanks go back on. Mark

[paulfun]

Markus I was looking at the front mounts close on this bike and think if you moved the mounts in a tad closer to the frame they would be way better off. Even with the new rubbers installed properly there was a slight gap between the rubber and the mount points.

I am drainning the tank as we speak so if I can find a way to get a pic of the area up in there I will post it.

[DSBeav]

Just in case there's someone out there that doesn't know one of the reasons why these mounts break in the first place......the tank rubbers have to be turned a certain way! If they are installed with the thick part of the tank rubber towards the frame......that's wrong!! Mark

Markus56,

Do you know if it is also wrong on the ZL900? I just replaced mine, and want to make sure I have them in right.

Thanks, Don

[paulfun]

Don yours are on correctly! I would have told you and fixed them when the tank was off here if theywasnt.

By the way you left your pods here. Dont think you left anything else but will know soon as I am cleanning the garage today.

[DSBeav]

I should have figured you were on top of it. Markus56 just worried me when he said that, cause I know how I put them in was large side toward the bike.

I was trying to get out the door quick as to not get you in more trouble with the woman...lol or me for that matter. I may need to get the pods. I wasn't thinking I would need them, but I have a line on another 900 and it is missing one pod.

Thanks, Don

[paulfun]

I will box them up for you

[wuputt]

I used JB weld on mine also. I don't want the downtime right now and have a ton of faith in JB! I used wire brush, sandpaper to strip n clean. Been through a few tanks of fuel and so far good to go!
I've been using JB for projects for prolly 30 years and it has rarely failed me! I had a 61 Ford Ranchero that had a gas tank rusted all around the seam. If I filled it it leaked down to half tank by the time I got home, wire brushed (hand) and smeared JB and never leaked again! Sold it to a friend who drove it for several years and it still never leaked!

[zlMark]

I did a temp repair on mine that has held on for a lot longer than temp! I used Seal-All and just coverend the entire mount, let it sit over night. That was over a year ago. My plan is to solder the entire tab.

My bushings are in with the large end outward both bikes, they fit the washer on the metal sleeves that way.

[paulfun]

Mark on the 900 the big end goes toward the frame.

[markus56]

Mark on the 900 the big end goes toward the frame.
This is the way mine fit the best too.....opposite of each other.

[zlMark]

i'll give it a try next time the tank is off

[kawboy]

My bushings are in with the large end outward both bikes, they fit the washer on the metal sleeves that way.

The diagram on kawasaki.com appears to show the thick end inward, though it's hard to tell. Just looked at mine and thick end is outward. I've replaced them several times over the years and that's the way they've always been. This bushing wears out pretty quickly.

Driving across Lousy-ana on a very crappy I-10 beat my right tank mount into submission. I attempted repair in a motel parking lot with one of the epoxy stick tank repairs. My prep was minimal given the working conditions, but these things can supposedly make "wet" repairs. Didn't hold.

When I got home home I cleaned the area real good and J-B'ed the crap out of it. This held for 6-7 years believe it or not. When it started leaking again I naturally went with J-B Weld again. For some reason it didn't last but a couple months. I have Seal-All on it now and it's seeping a little. I have sinced learned that each layer of Seal-All should be allowed to dry before applying another layer.

Anyway, I'll have to do something soon. I have another good tank, but it's black, and my bike is wineberry. Don't have the funds to paint it right now - though I've thinking about going FLAT BLACK!

[Bacchus]

my zl 1000 doesnt leak..whats the story here?

[zlMark]

nice smooth roads?