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Fuel tank overflow leak

This is a discussion on Fuel tank overflow leak within the ZX-12R forums, part of the Kawasaki Motorcycles category; Well, after doing some research on this site and entering my bikes VIN# into the Kawi site's warranty status page, I'm relatively sure that I'm ...


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Old 01-26-2012, 07:29 PM   #1
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Fuel tank overflow leak

Well, after doing some research on this site and entering my bikes VIN# into the Kawi site's warranty status page, I'm relatively sure that I'm experiencing the "Fuel Tank Overflow Pipe Cracking" issue. It just recently started to leak fuel from the overflow tube at a very slow, but steady rate. I fear that the leak will get worse. My bike was out of warranty in Oct. of 2001, but it still lists 2 outstanding recall repairs...one being the cracked pipe / fuel level sensor recall, and the other being the oil seepage from alternator lead connector. Is there any chance that Kawi would still honor these recalls? The bike only has 5,000 original miles on it. I'm the second owner, and the original owner had the bike in storage for nearly 10 years. (long story, explained on another thread). Thanks for any input or suggestions.
   
 
Old 01-27-2012, 10:30 AM   #2
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Someone correct me if I am wrong, but I think that as long as recall hasn't been documented as being done that it has to be done and covered by a dealer.

They ended up replacing the entire tank on my 2000 A1 years ago because the tube was cracked to the point that it wasn't fixable, or at least that is what they told me.
   
 
Old 01-27-2012, 10:33 AM   #3
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They replaced the whole tank on mine & it was 8 years old at the time!
So you should be able to get it fixed free of charge?
good luck.
   
 
Old 01-27-2012, 10:49 AM   #4
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Well, I contacted a local Kawi dealer and explained the situation. He took my VIN# over the phone and said that the two recalls are still covered. He asked me to bring the bike in tomorrow so he can verify the problem, and then he'll order the parts. I'm guessing that a new tank is necessary, since the damage is done. If a new tank is in the cards, I assume that they'll install the lead weight on the internal overflow tube to prevent it from cracking again? Does anyone know if the tanks from later model ZX12's have the same recall issue, or did Kawi correct the problem for the '02-'05 models?
Guess I should push for the alternator lead wire fix while I have it there.
   
 
Old 01-27-2012, 04:31 PM   #5
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By the time I took mine in it would leave a puddle of about 3 foot in diameter.

It didn't take mine long to get to that point either. A couple weeks maybe, tops?
   
 
Old 01-28-2012, 12:44 PM   #6
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Under the recall, the dealership is ordering me a new fuel tank and fuel level sensor. The fuel gauge seems to be performing fine, but it's included in that particular recall, so I guess they're going to replace it anyway. The drip frequency out of the overflow tube is increasing. I have it draining into a small gas can. The alternator lead wire showed no signs of oil anywhere, and the plug was in great shape. If it starts to become a problem they will perform the fix.
   
 
Old 02-02-2012, 06:43 PM   #7
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Service Mgr. at my dealership called me a few days ago to tell me that the tank has been ordered, but it has to come from Japan, so he's thinking 3-4 weeks. He also informed me that the my bike's VIN did not fall in the range for the fuel level sensor recall.
I have a trip to the GA mountains planned for late April. Just hope this doesn't drag-out from weeks to months for the new tank.
   
 
Old 03-03-2012, 07:26 AM   #8
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Had the new fuel tank installed this morning. Hopefully the new one doesn't develop the same issue...time will tell, I guess. Glad to see that Kawi stepped-up and honored a recall issue from 12 yrs. ago. Surprised that they did, actually.
   
 
Old 03-03-2012, 10:03 AM   #9
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This is a safety recall issue, so they would get in trouble with the DOT if they didn't honor it. If you should grenade a clutch basket or trans or have a stator problem, you're S.O.L.!
   
 
Old 06-11-2012, 11:10 AM   #10
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This thread has been very helpful! I have a 2000 that I just got the end of March from the original owner... 7100 miles at purchase. HAving the same leak I just called Kawi to see what they know on the recall and what they can do for me. Didn't sound to willing to help over the phone, but they are looking it up for me now and I'm waiting for a call back. Will keep you all posted!
   
 
Old 06-11-2012, 12:59 PM   #11
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You'll get a brand new tank. They'll use your existing fuel cap and some other hardware from your original tank. They will then destroy your original tank with a sledge hammer and take a photo of it to send to Kawi...to guarantee that it's completely taken out of circulation. My local dealership was great through the whole process. Best of luck.


A couple pics from the tank replacement...



After having the wheels powder coated satin black...
   
 
Old 06-11-2012, 07:46 PM   #12
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I just had my 2000 ZX12R at the dealer last month. They did the oil seepage from alternator, valve stem lock nut, and fuel tank overflow recalls. They didn't replace my fuel tank. The invoice has part# 99996-1327 which says drain pipe kit. For the oil leak they only replaced the foam wiring harness "clamp" part number 92171-1255. I already had the fairings off for paint so ofcourse i went over everything they did as soon as i got it home. The plug for the regulator was still full of oil which I cleaned out myself. I could not see where anything had been done and I verified that the stator cover had not been removed. I will check this weekend to see if it is still leaking.
   
 
Old 06-14-2012, 10:22 AM   #13
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Quote:
You'll get a brand new tank. They'll use your existing fuel cap and some other hardware from your original tank. They will then destroy your original tank with a sledge hammer and take a photo of it to send to Kawi...to guarantee that it's completely taken out of circulation. My local dealership was great through the whole process. Best of luck.


A couple pics from the tank replacement...



After having the wheels powder coated satin black...
All local dealerships within 30 miles of me are really not appearing to impressing me in regards to this situation. They don't really seem to even want to do the fix. One guy even said the bike is 12 years old, if your not having any issues I would... I then had to cut him short and remind him that I have a coating of fuel on the ground at every stop. Why would they need to have the bike and keep it while they order the parts? You could be talking 2-3 weeks of them just holding the bike. Unacceptable. One shop that actually set up an appt wants to bring it in on the 28th of this month and will not even LOOK at it until AFTER the 4th of July weekend! Not even begining work or ordering parts!
   
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