Leaking gas tank and need help identifying said tank.

Thanks for all the invaluable info Martin!
I did see that last mounting option in the manual and I don't see that currently working on this bike.
I guess I could try and find that damper but I think I'll just keep the current tank. Maybe paint it in some fun color and be happy with that!

Assuming the D4 tank damper is the same, it was used on many KZ models, so you can probably find one. Partzilla seems to indicate that it's still available from the Kawasaki dealer & there are quite a few new tank dampers listed on EB. Used are probably available as well.

DAMPER RUBBER FUEL Tank # 92075-295
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So, an update on the leaking tank issue.

This is how it looked, no idea what was hiding underneath that:


Oh look! After using a hammer and knife I was able to chisel out a Fuel gauge


Most of the epoxy or whatever it was removed. Area sanded and painted:



Fuel gauge attached again with a gasket made from gasoline proof gasket material that you can cut yourself into the right size:



It probably needs a touch-up with paint but at least want to try if this fix will work.
What do you guys think, will it hold? :side:


Aand bonus custom mounting for the gas tank, whatever model it is haha.....

The gasket will probably work fine, but I used an o-ring from a metric nitrile o-ring kit.
Installing a round o-ring in the oblong groove required some manual dexterity, but it wasn't hard to do.

Also, the fuel switch tends to leak at the red plastic piece, so keep an eye on that. Mine was seeping a little there but not much, so I sealed it with Permatex liquid metal. After drying, it's kind of like plastic & not brittle, so it won't crumble. I did the repair several years ago & it's still good.

Seal-All is another product that might work to repair minor fuel leaks, but I've never used it. Seal-All advertises that it's fuel proof
and others here on KZR have reported using it.
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Thanks for the heads-up on the red plastic bit, I'll keep a look out for that.
Maybe I'll even try to get the Fuel Gage to work as well

Martin_csr
So you were correct, it's still seeping out of that little red plastic piece and I had no luck trying ti sell it with "form-able metal"...
I also kind of want a fuel gauge now actually, do you happen to know what gauge i got? I'm still not sure what tank I have so not sure what I should be looking for as a replacement.


Could it be this one? www.partzilla.com/product/kawasaki/27010-1096
Fuel Switch 27010-1096?

Thanks!

The cross-reference in your link is showing the earlier 650D models, so it's probably correct. The same fuel switch o-ring is used on many Kawasaki models, so that one will probably fit fine & they all probably work the same. My 81 KZ650-CSR, fuel switch is 27010-1055 >> the -1096 fuel switch is about 8mm taller, so it will illuminate sooner than mine.

Here's a NOS 27010-1096 fuel switch that I measured & compared to a 27010-1055 fuel switch. I plugged it into the wire harness a while back & it functions the same. The original one on my motorcycle was problematic, so I was trouble shooting to make sure the problem wasn't the wire harness >> the fuel switch pigtail needed to be repaired. You could probably repair yours.

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My D4/SR tank:

Awesome info guys,

I ordered the fuel gauge with part number 27010-1096 and it fit like a glove.
Also ordered the rubber dampers for the original tank, will fit with some modification since I got something looking like the CSR tank and custom welded brackets on the frame and tank.
Will paint the tank as my next step and see if I can hook up the new fuel gauge and get that working.

Almost there!

No eBay APP ID and/or Cert ID defined in Kunena configurationDAMPER RUBBER FUEL T
92075-295