KZ900 Generator Cover Oil Leak: Complete Solution! PAMS Viton Grommet is Absolutely Fantastic

PAMS Viton Generator Cover Grommet

The Kawasaki Z-series generator wiring layout is quite problematic.
The Suzuki GS1000 and GSX1100S came later, so they’re completely sorted out.

We’ve been hunting for that stubborn weeping spot, but PAMS has released an amazing product, so
from now on we’re using this Viton version. No more seeping or leaking from here on out!

Viton barely shrinks from heat or gasoline

In a word:
**“Expensive, but top-tier rubber with outstanding resistance to heat, oil, and chemicals.”**

Detailed characteristics:

• What it is: A type of fluoroelastomer (FKM), a trademark of Chemours (formerly DuPont).
• Advantages: Exceptional heat resistance, oil resistance (including gasoline), chemical resistance, and UV resistance. It withstands environments where ordinary black rubber (like NBR) would dissolve or harden.
• Disadvantages: High cost. Also vulnerable to certain solvents (ketones like thinner) and extreme cold.
• Common applications: O-rings, seals, and fuel hoses inside engines and other harsh environments.

Difference from nitrile rubber (NBR): Standard oil-resistant rubber (NBR) is even more resistant to heat and gasoline than Viton. Wait, that’s backwards—Viton is the one that’s stronger.

We ended up rebuilding from the base.

The wire insulation was damaged, so we re-bonded it from the root.
Splice crimping and soldering for a perfect job.

Silicone glass tubing for a perfect seal.

Let’s check the contact points.

You’d need to build it up quite a bit for contact. Phew, that’s a relief! (*´ω｀*)

If we keep the grommet side pulled tight, there shouldn’t be any contact.

Epoxy for insurance. Fix the grommet first and let it cure.

After checking the right length, we fill the grommet groove with epoxy.
Masking beforehand makes for a clean fill! (*´ω｀*)

Using a thin flathead screwdriver to fill bit by bit gives the cleanest result.
ThreeBond TB2081D

Apply a thin coat to both the cover side and grommet side.
Applying too much just squeezes out, so minimal is fine.

Leave it fixed like this for about 24 hours to cure.
It’s a surprisingly time-consuming job… learning something new every day!

We made a fixture plate too, so next time we can handle it right away.
*We cut threads into the plate, so no nuts needed.

We’ll use braided tubing for the covering.

That’s how we completed the oil leak fix.
Definitely use the PAMS Viton grommet—it’s the way to go!

To be continued.