SuzukiSavage.com - Gas Tank Problem

Michael

Ex Member

Gas Tank Problem
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

Back to top

IP Logged

torque

Serious Thumper
2005 No Login

Offline

2008 nightster,flat
od green and black

Posts: 748
rock hill,S.C.
Gender: male

Re: Gas Tank Problem
Reply #1 - 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.

Back to top

IP Logged

Savage_Greg

Serious Thumper
Alliance Member

Offline

Don't go around your
ass to reach your
elbow...

Posts: 7844
SW Washington State
Gender: male

Re: Gas Tank Problem
Reply #2 - 09/25/05 at 07:15:06

Michael wrote on 12/31/69 at 16:00:09:

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.

Back to top

IP Logged

klx650sm2002 Serious Thumper Offline The more I learn the less I know. Posts: 2041 Cumbria,England Gender:	Re: Gas Tank Problem Reply #3 - 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
Back to top	IP Logged

Michael

Ex Member

Re: Gas Tank Problem
Reply #4 - 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

Back to top

IP Logged

Savage_Greg

Serious Thumper
Alliance Member

Offline

Don't go around your
ass to reach your
elbow...

Posts: 7844
SW Washington State
Gender: male

Re: Gas Tank Problem
Reply #5 - 09/26/05 at 06:45:27

Michael wrote on 12/31/69 at 16:00:09:

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.

Back to top

IP Logged

Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Gas Tank Problem Reply #6 - 09/26/05 at 07:19:52 Savage_Greg wrote on 12/31/69 at 16:00:09: 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.
Back to top	1998\|MAC muffler\|ceramic coated header\|K&N air filter\|Amal Mk2 carb\|Odyssey battery\|iridium plug\|NC windshield\|Dunlop 491s\|Superbrace\|EBC brake rotor\|12.5" Progressive shocks\|Kuryakyn ISO grips IP Logged

Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Gas Tank Problem Reply #7 - 10/02/05 at 09:02:45 Savage_Rob wrote on 12/31/69 at 16:00:09: 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.
Back to top	IP Logged

sluggo Serious Thumper ModSquad Offline big singles lead, twins follow the pack Posts: 4744 moses lake washington Gender:	Re: Gas Tank Problem Reply #8 - 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.
Back to top	SINGLES RULE, HARLEYS DROOL IP Logged

Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: Gas Tank Problem Reply #9 - 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.
Back to top	Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink IP Logged