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TOPIC: Kz1100 Fuel tank leak from side

Kz1100 Fuel tank leak from side 08 Jun 2020 10:18 #827591

  • chrisM
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Hi Everyone,

Hoping someone has some good advice here. I have an '82 Kz1100 A2 Shaft with a nice 5 gallon tank. For years now, gas has been seeping out of the side of the tank where the Kawasaki emblem once was. The tank was spray-painted by a previous owner and you can see the candy red painted some rust coming through a bit as the leaking fuel seems to be deteriorating the wood. I was in denial about the leaking fuel for a long time, but I've come to accept it and am trying to figure out what to do.

The inside of the tank had been very rusty. 2-3 years ago, I had the tank acid washed and coated at a radiator shop when I was in a pinch. I have looked around for a replacement tank, but it's tough to find and the ones I have found are pricy and just as rusty.

I have read mixed reviews about repairing a tank and wonder how that would work now that the entire inside has a coating.

Any help would be awesome!
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Kz1100 Fuel tank leak from side 08 Jun 2020 16:26 #827621

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The inside coating complicates thing. I think it's going to have to be stripped before the leak can be fixed.

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Kz1100 Fuel tank leak from side 09 Jun 2020 16:16 #827706

  • Highway Magician
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This product will take care of the problem. I would remove the tank and lay it on its side, then take a small brush and apply it to the outside of the tank.
I have used it before on a leaking gas tank seam and it stopped the leak completely. It really is hard as a rock when it dries.

Motorcycle builder since 1973. Got a G3 running back then. The throttle stuck on the test-ride.
Been a Kawasaki fan ever since! Master Tech. Current bike: 1982 GPZ1100B2.

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Kz1100 Fuel tank leak from side 12 Jun 2020 23:16 #828036

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That's what I'm wondering about. The inner lining is going to be difficult to remove...

Por Patch SOUNDS like a great solution and definitely worth trying. If I can fix this for less than $20, that's ideal. They say you can apply it directly over rust as well. I would sand off the paint first and get down to the raw metal before trying to apply that though, no?
My worry is that:
A.) I expose a big leak that I may not be able to fix right away
and
B.) the rust that is going through the tank will continue to spread anyway, regardless of what I put on top and I will have another leak down the road.

Have you used this product for a leak like this in the middle of the tank or just for seam work?

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Kz1100 Fuel tank leak from side 13 Jun 2020 05:17 #828041

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Stripping a failed liner is not fun but it is doable. I've had best success with high strength methaline chloride paint stripper. I've read that MEK works well too. To derust I like phosphoric acid. You are going to have to strip off the body mud over the tank badge bars and preferably, remove the bars completely. Small leaks can be sealed by silver brazing or using body solder. Once the tank is fully derusted inside and out then you can apply a new liner using POR-15 or similar. Just don't use Kreem since it's got a pretty bad reputation.
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Kz1100 Fuel tank leak from side 13 Jun 2020 06:55 #828045

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chrisM wrote: That's what I'm wondering about. The inner lining is going to be difficult to remove...

Por Patch SOUNDS like a great solution and definitely worth trying. If I can fix this for less than $20, that's ideal. They say you can apply it directly over rust as well. I would sand off the paint first and get down to the raw metal before trying to apply that though, no?
My worry is that:
A.) I expose a big leak that I may not be able to fix right away
and
B.) the rust that is going through the tank will continue to spread anyway, regardless of what I put on top and I will have another leak down the road.

Have you used this product for a leak like this in the middle of the tank or just for seam work?


I used it for sealing the seam on a gas tank but it will seal anything. It's POR-15 in a toothpaste-like form.
What it hardens, it's like a marble.

You can remove any existing tank liner with aircraft paint remover.

I use Evaporust for rust removal inside of a gas tank. Caswell makes a good epoxy gas tank liner.
Motorcycle builder since 1973. Got a G3 running back then. The throttle stuck on the test-ride.
Been a Kawasaki fan ever since! Master Tech. Current bike: 1982 GPZ1100B2.
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Kz1100 Fuel tank leak from side 19 Jun 2020 12:09 #828475

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Thanks for all the tips. I have talked to a lot of people and looked at a lot of videos and I think clearing out the inside of the tank is not something I want to do...

I think I'm just going to strip all the paint off to the bare metal and see how it looks. Hopefully I can sand it down a bit, put some of that POR 15 on wherever it's leaking from. Prime, paint and clear coat it and call it a day.... for now. I've had such a headache with this gas tank in the past and the person who lined it told me what a pain it was to acid wash the rust out of it - I don't want to go down that path again with the liner.

I'll update later

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Kz1100 Fuel tank leak from side 20 Jun 2020 16:44 #828550

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Any advice for removing the bars?

Seems like they are on there pretty good. I've poured solvent all over it a few times and tried prying them off, but only got the ends to bend up.

I'm stripping the paint now and there's some bonds and a bunch of pin holes. Looks like the bike took a digger or was tipped.
Gonna do a full re-do on the inside. The lining I had has deteriorated and the inside is full of rust... again...

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Kz1100 Fuel tank leak from side 20 Jun 2020 21:06 #828560

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The bracket is dot welded 3 times in to the tank depression.

kzrider.com/forum/6-paint-a-bodywork/612...is-tank-toast#818039

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Kz1100 Fuel tank leak from side 21 Jun 2020 15:11 #828612

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If you pry off the bar the spot welds will tear and you will have holes in the tank. You could try grinding the bar on top of the spot welds, just don't go too deep.

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Kz1100 Fuel tank leak from side 29 Jun 2020 18:57 #829397

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I’ve baked a tank in a powder coating oven then blasted the inside of it out then cleaned it with vinegar. It got one of them cream liners out. The tank looks great now after my first tank paint job. I’d get that liner out if it was mine.
It had a crack across the face of the tank with a dent. So after all the baking and cleaning I braised the crack closed. It worked pretty slick , I wonder if you could do that without removing the badge mount
82-KZ1100-A2 shaft
82-GS850g shaft
81- kz1000 Ltd 1075

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Last edit: by Inline88.
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