SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Gas Tank Problem /cgi-bin/YaBB.pl?num=1127647988 Message started by Michael on 09/25/05 at 04:33:08

Title: Gas Tank Problem Post by Michael on 09/25/05 at 04:33:08 Hi all: As i was out for a pleasure ride this week, I noticed a strange thump every time I hit a bump. I pulled over and discovered what i thought to be the bolts loose on the gas tank, where it mounts by the seat. It seemed to have a lot of play in that particular area. I thought "No Biggie" I will tighten the bolts. I decided yesterday that I would pull the seat and tighten the two said bolts. To my dismay, it was not the bolts. It seems the weld has broke, where the bracket connects to the tank. It broke off flush with the tank, with hardly an edge at all. Has this happened to anyone else? I find it very odd, as i don't ride any particularly bumpy roads, and avoid potholes, manholes, etc. The bike is a year 2000, with only 10,000 miles. Perhaps it was defective. I really don't want to have to replace the tank, as price, and color match are my two main concerns. The paint on this tank is mint. I know nothing about welding. To those of you that do, is it possible to weld this? Is the metal too thin under the tank? It seems fairly clean, with no rust at all.  I am hoping to go this route, as the riding season is all but over here, and i will be pulling the tank in a month or so to do the oil leak/plug fix. Opinions welders? Thanks! cheers Michael

Title: Re: Gas Tank Problem Post by torque on 09/25/05 at 06:56:53 I am in the middle of preping my frame for paint,which means i have to grind all the welds down,and i can definately believe that your bracket broke ,i cant beleive the savage stays together with such crappy welds,it seems to me like a three year old did my frame! But u can weld the gas tank,i would use a mig welder.But make sure there are no  fumes left in the tank i would have a local welder do it though,because its his fault if he ruins the tank.

Title: Re: Gas Tank Problem Post by Greg_650 on 09/25/05 at 07:15:06 Michael wrote: Hi all: As i was out for a pleasure ride this week, I noticed a strange thump every time I hit a bump. I pulled over and discovered what i thought to be the bolts loose on the gas tank, where it mounts by the seat. It seemed to have a lot of play in that particular area. I thought "No Biggie" I will tighten the bolts. I decided yesterday that I would pull the seat and tighten the two said bolts. To my dismay, it was not the bolts. It seems the weld has broke, where the bracket connects to the tank. It broke off flush with the tank, with hardly an edge at all. Has this happened to anyone else? I find it very odd, as i don't ride any particularly bumpy roads, and avoid potholes, manholes, etc. The bike is a year 2000, with only 10,000 miles. Perhaps it was defective. I really don't want to have to replace the tank, as price, and color match are my two main concerns. The paint on this tank is mint. I know nothing about welding. To those of you that do, is it possible to weld this? Is the metal too thin under the tank? It seems fairly clean, with no rust at all.  I am hoping to go this route, as the riding season is all but over here, and i will be pulling the tank in a month or so to do the oil leak/plug fix. Opinions welders? Thanks! cheers Michael That's different.  I have to ask, "Why?"  Did you do any mods like raising the front of the seat? Just remove the tank.  Remove the petcock and gas cap.  Take it to a small welding shop.  Shouldn't be a problem to fix....$20 or so.

Title: Re: Gas Tank Problem Post by klx650sm2002 on 09/25/05 at 07:51:10 Put the tank on a car exhaust for a couple of minutes, gets rid of the fumes. Clive W  :D

Title: Re: Gas Tank Problem Post by Michael on 09/25/05 at 20:42:20 Thanks guys, for the quick responses. I too am quite shocked at the fact that this weld broke. To answer Greg's question. I have not modified or done the seat lift as of yet, but planned on doing it soon.  The bolts are firmly in place, and not a bit loose. Maybe the fact that i didn't do the seat mod is a contributing factor. I find myself up against the tank far too often, and have to keep sliding back. I am about 200 pounds, so perhaps all the pressure of my weight has broken a weld, which was inferior. The tank has only been off the bike no more than 3 times, as far as I know, for spark plug changes. cheers Michael

Title: Re: Gas Tank Problem Post by Greg_650 on 09/26/05 at 06:45:27 Michael wrote: Thanks guys, for the quick responses. I too am quite shocked at the fact that this weld broke. To answer Greg's question. I have not modified or done the seat lift as of yet, but planned on doing it soon.  The bolts are firmly in place, and not a bit loose. Maybe the fact that i didn't do the seat mod is a contributing factor. I find myself up against the tank far too often, and have to keep sliding back. I am about 200 pounds, so perhaps all the pressure of my weight has broken a weld, which was inferior. The tank has only been off the bike no more than 3 times, as far as I know, for spark plug changes. cheers Michael Considering the portion of your anatomy that is in contact with the tank, I doubt you broke it :) Forget the seat mod unless you need to change the angle.  You'll still get monkey butt.

Title: Re: Gas Tank Problem Post by Savage_Rob on 09/26/05 at 07:19:52 Greg_650 wrote: Forget the seat mod unless you need to change the angle.  You'll still get monkey butt. True but I think a lot of folks find the modified angle more comfortable.

Title: Re: Gas Tank Problem Post by Greg_650 on 10/02/05 at 09:02:45 Savage_Rob wrote: True but I think a lot of folks find the modified angle more comfortable. They might, or then it could be imagined.  Me, I fought back my skepticism and the made the change.  I found no benefit.

Title: Re: Gas Tank Problem Post by sluggo on 10/02/05 at 10:42:09 my gn 400 had the same problem.. it was welded then i put a tank sealer in it.. worked great.

Title: Re: Gas Tank Problem Post by Ed_L. on 10/02/05 at 11:49:59 That is the second tank that I have heard about that has broken there. There was one about a year ago on a different board that had that mounting tab break off. Luck with the repair.

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