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Having a hardcoded value is a poor technique.

Here's what I'm testing with:

X</channel>
</rss>

The debug print out:
before len=19
offset=1 fSize=19 content.len=3

What is the -18 for?

insert(file.getPath(), file.length()-18, insert);
Can you make a minimum sized .xml file? Maybe 5 lines.

Can you make a much smaller test.xml file so its easier to see what happens.

Sorry, I don't want the full code. I don't use eclipse.
Can you make a Short, Self Contained, Correct Example for testing?

Can you make a Short, Self Contained, Correct Example for testing?

What's in the file that is being written to? Does the code skip over one character that appears as a random character?

Is it always the letter Z and in the same location?

Where in the code does the "Z" first appear? Add some debug statements to test all Strings for "Z" and to print that String when it is found.