2009 TZI Owners Major Problem!!! Look Here Options

[Snowride]

A fellow on our local Quebec forums found this problem on his sled so I decided to check mine out just for safety sake.

Not good at all. There is an unused engine mount that is rubbing on the gas tank and scoring it pretty bad. I only have about 700 miles on mine but there already is a good 1/8" gouge in my gas tank. If this continues like this I'm afraid of what could happen. (IMG:style_emoticons/default/flame.gif)

Cat Canada and Cat USA have been sent these pictures so lets see what they have to say about this. Personally I fixed mine as I'm definitely not going to wait till summer before somebody makes a decision!!!

I have to assume this is only applicable to the 2009 models as the tank was upgraded in size for 09. If this portion of the tank is the same on earlier models then they may be affected also.

Unfortunately the tank needs to come out to see and address the problem and if you know what you are doing I would say it's a 1 1/2 hour job.

Here is the culprit. The screw driver tip is pointing to the engine mount where it makes contact with the tank. This engine mount is not used at all.


(IMG:http://i40.tinypic.com/359hctk.jpg)


Here is what the damage to the tank looks like. Pretty hard to see but it is at least 1/8" deep already!!


(IMG:http://i42.tinypic.com/m7rex4.jpg)


In this picture you see a close up of the engine mount. Right on the sharp edge of this is where the tank is rubbing.


(IMG:http://i40.tinypic.com/14m3r6f.jpg)


As this engine mount is not used in any form or fashion, I simply ground away material to give it the required clearance as shown here.


(IMG:http://i39.tinypic.com/125261d.jpg)

This post has been edited by Snowride: Feb 1 2009, 03:07 PM

[drag cat 980]

A fellow on our local Quebec forums found this problem on his sled so I decided to check mine out just for safety sake.

Not good at all. There is an unused engine mount that is rubbing on the gas tank and scoring it pretty bad. I only have about 700 miles on mine but there already is a good 1/8" gouge in my gas tank. If this continues like this I'm afraid of what could happen. (IMG:style_emoticons/default/flame.gif)

Cat Canada and Cat USA have been sent these pictures so lets see what they have to say about this. Personally I fixed mine as I'm definitely not going to wait till summer before somebody makes a decision!!!

I have to assume this is only applicable to the 2009 models as the tank was upgraded in size for 09. If this portion of the tank is the same on earlier models then they may be affected also.

Unfortunately the tank needs to come out to see and address the problem and if you know what you are doing I would say it's a 1 1/2 hour job.

Here is the culprit. The screw driver tip is pointing to the engine mount where it makes contact with the tank. This engine mount is not used at all.
(IMG:http://i40.tinypic.com/359hctk.jpg)
Here is what the damage to the tank looks like. Pretty hard to see but it is at least 1/8" deep already!!
(IMG:http://i42.tinypic.com/m7rex4.jpg)
In this picture you see a close up of the engine mount. Right on the sharp edge of this is where the tank is rubbing.
(IMG:http://i40.tinypic.com/14m3r6f.jpg)
As this engine mount is not used in any form or fashion, I simply ground away material to give it the required clearance as shown here.
(IMG:http://i39.tinypic.com/125261d.jpg)

wow, good find, i wonder if the z1 turbo would be the same way, i think they have the same capasity tank,

[Snowride]

wow, good find, i wonder if the z1 turbo would be the same way, i think they have the same capasity tank,

I'm pretty sure they would also be the same. I forgot to mention this IS the Turbo!!!

This post has been edited by Snowride: Feb 1 2009, 07:07 PM

[Snowride]

Wow, over 250 views and nobody seems to give a hoot that there gas tank is about to fail. This affects the TZ1 Touring Turbo like mine and I'm 99% sure it also affects the 1 up Z1 Turbo and Sno Pro Turbo and probably the non Turbo also. Any 2009 Z1 Turbo or Non Turbo most likely has the same issues as above.

[Blackhammer]

damn.... (IMG:style_emoticons/default/veryangry.gif)

Another evening in the garage...

Good find indeed.

[Snowride]

Personally I have never done so much preventative crap to a sled as this. Never paid this much for a sled either!! While I had the gas tank out I decided to reroute a lot of wiring which looked to be problematic in it's original location. The worst one was the CCU wire which WAS completely crushed between the aluminum frame and the tank. It is now routed on the outside of the frame where it does not bind at all.

[hallnracing]

I think there is supposed to be a foam block on the aluminum support on top of the tank, to hold the tank more to the right. Looks like it might fall out easy.

[Snowride]

I think there is supposed to be a foam block on the aluminum support on top of the tank, to hold the tank more to the right. Looks like it might fall out easy.

Actually it is a rubber strip which looks like a feeble attempt to maybe push the tank to the correct side but I really do not see this doing much at all. Mine was in place and had not fallen out.

[Vince]

Thanks for the heads up, mine is rubbing there and on the adjuster for the cam shaft chain.

[old cat man]

I wonder what that hole is for since Cat and Suzuki build that for Cat so why add an extra hole? Good find.

[catchmeifucan]

this info sud save a few bonfires! this not meant as a joke, read a few weeks ago about a few of them burning up, and this may be the culprit!

[GreenStreak]

I wonder what that hole is for since Cat and Suzuki build that for Cat so why add an extra hole? Good find.

that mount,will be used for extra engine torque,created by a second turbo(yup,twin turbos),when that engine is put in the chassis Cat is working on.it will be a late 2010 release.end all,beat all sled.you think they are gonna let Doo take over with the 1200 etec?

[PHJ]

Is there anyway that you can see in that area.....mirror, flashlight, etc to see if you have a problem without tearing the sled apart? Also sitting on the sled looking forward is it on the right or left side?

[drag cat 980]

Is there anyway that you can see in that area.....mirror, flashlight, etc to see if you have a problem without tearing the sled apart? Also sitting on the sled looking forward is it on the right or left side?

this is a good question, i think its on the throttle side but not sure, i pulled the side pannels and cant see crap, alot of stuff in the way, from what i can see mine may be fine, please help us out, thanks, ben,

[Snowride]

Is there anyway that you can see in that area.....mirror, flashlight, etc to see if you have a problem without tearing the sled apart? Also sitting on the sled looking forward is it on the right or left side?

Actually yes you can see it but only very slightly. If you remove the pod and shine in at the exact location which is on the throttle side you will see a little white scratch mark (at least I did on mine) Obviously you cannot see around the corner but maybe if you have the right kind of telescopic small mirror it can be seen entirely. I assume Cat won't wait too long to tell us what they will do. Only feasible thing is a massive recall on all Z1 sleds to grind away the motor mount just like I did.

If this helps any, the first picture above is taken from the back looking forward with the tank removed. The tank actually curves around the motor mount. Here is a bigger picture of the tank but maybe more confusing than anything else. Definitely the most complicated tank ever made.


(IMG:http://i44.tinypic.com/jgtqmx.jpg)

This post has been edited by Snowride: Feb 2 2009, 07:07 PM

[PHJ]

Actually yes you can see it but only very slightly. If you remove the pod and shine in at the exact location which is on the throttle side you will see a little white scratch mark (at least I did on mine) Obviously you cannot see around the corner but maybe if you have the right kind of telescopic small mirror it can be seen entirely. I assume Cat won't wait too long to tell us what they will do. Only feasible thing is a massive recall on all Z1 sleds to grind away the motor mount just like I did.

If this helps any, the first picture above is taken from the back looking forward with the tank removed. The tank actually curves around the motor mount. Here is a bigger picture of the tank but maybe more confusing than anything else. Definitely the most complicated tank ever made.
(IMG:http://i44.tinypic.com/jgtqmx.jpg)

Snowride,

It just came to me what the difference is between what you have posted and my sled. Is the inside of your tank Black or White? When I fill mine, the inside is definitely white yet I assume that the outside is black. Is the tank by chance double-lined, can you tell seeing yours is apart?

[Snowride]

Snowride,

It just came to me what the difference is between what you have posted and my sled. Is the inside of your tank Black or White? When I fill mine, the inside is definitely white yet I assume that the outside is black. Is the tank by chance double-lined, can you tell seeing yours is apart?

Yes the tank is double lined. White on the inside and black on the outside. Almost looks like they are somehow moulded together as 1 piece. This would make it rather thick but non the less the gouging will eventually make it through.

[Vince]

Snowride,

It just came to me what the difference is between what you have posted and my sled. Is the inside of your tank Black or White? When I fill mine, the inside is definitely white yet I assume that the outside is black. Is the tank by chance double-lined, can you tell seeing yours is apart?

Good point Paul, due to EPA regs all gas tanks are now double walled to prevent fumes from seeping out of the plastic.

[Snowride]

TTT

[mariobross55]

I think there is supposed to be a foam block on the aluminum support on top of the tank, to hold the tank more to the right. Looks like it might fall out easy.

HI Guys...

I am the guy who found out that shaving, I removed the gaz tank to get access to the ISC control valve... and I found out that problem... and to to answer your question yes there there two pieces not foam plus solid rubber to force to thank to the most right position and they are still there like Snowride... I buff off the holding post on the engine which is not used ... with a kind a Milwaukee small camera (Home depot Store) you will be able to get at that location and have a look... but I will be surprise if there is room the tank realy fit tight in the sled..... just be aware....

Mario