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leaking fuel tank; leaking fuel tank
Topic Started: May 11 2014, 06:33 PM (460 Views)
Zedgeezer
Member
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I have got a split on the seam of my 25 yr old kawasaki ZL1000 fuel tank, it is really minor (and can't be seen by the naked eye) but obviously a big deal in real terms. Has anyone got any suggestions how it can be fixed? I know there are all sorts of rules about welding fuel tanks and accept the fact that a total respray may be required, but as the tank has now been fuel free for several years (ie bike has been garaged because I couldn't afford to get it sorted) I didn't know if there was a cheap option. I guess a new tank at around a £1200 may be the only other option? I am located in the East of England but would probably travel almost anywhere to get this bike back on the road.
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jacko73
Member
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Hi. Im kinda new to this forum stuff so please bear with me if I drop any clangers with my posts and replies.

Your leaking tank? You mention that the leak cannot be seen,but its there (most annoying!)
How about soldering it with thick solder and using a blow lamp? Ive done this before with great results on both bike petrol tanks and stationary engine tanks. As long as the damage/split/rust pinholes are not too big then with time,patience and loads of preperation it can be repaired and the fettling off afterwards is alot easier too as the solder will run nice and deep into the damaged area.
As long as theres no petrol fumes left then its worth a shot,but just to be on the safe side Id leave the cap open for a week and then give it a right good swill out with hot soapy water and then go for it.
Hope this may help
Rob
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andy-750
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Grand Master Poster
you can get an epoxy for tanks similar to magic metal but would suggest giving the tank a complete going over by stripping it and getting it welded as bound to be rust in other places
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yellowbelly
200 MPH
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These epoxy resin sealers work very well .Just make sure you get one that will be ok with ethanol fuel and you should have no problems .
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Deleted User
Deleted User

Check out cleaning and repairs to fuel tanks on you tube.
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