1. 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
    WR = 2st Enduro & CR = 2st Cross

125-200cc how can I fix/replace the gas tank bolt post?

Discussion in '2 Stroke' started by PC., Oct 23, 2014.

  1. PC. Husqvarna
    AA Class

    Location:
    Beaverton, OR
    Husqvarna Motorcycle:
    CR165 & CR144
    Other Motorcycles:
    KTM500
    I broke the gas tank bolt on my 2009 bike and in my attempt to extract it... I broke the extractor off. To make a long story short, I've pretty much ruined the OEM post and need to replace it.

    Does someone sell a pre-threaded post I can weld onto the frame? Or will I need to buy a solid post, weld it on and then tap new threads?

    Or if anyone happen to have an easier solution I am all ears. thanks!
  2. ajaxauto Husqvarna
    Pro Class

    The older husky like 2006 to maybe 2008 have the longer post where the gas tank bolt last longer Then the newer ones where the post is shorter and then you have a spacer and a longer bolt that brakes a lot


    So what you can do is get a regular grade 5 bolt grade 8 is to hard to tap Get a long bolt about the size of your now post cut the bolt to size needed weld it on then drill it and tap it i now get a new gas tank bolt put it on and you are done.


    I like to tack the center bolt to the frame put on the tank make sure all is centered then remove tank and weld the new post easy and cheap
    PC. and kx3089 like this.
  3. steadydirt Husqvarna
    AA Class

    Location:
    Ontario
    Husqvarna Motorcycle:
    2007 2002 wr 250 1994 wxe 250
    Other Motorcycles:
    fj 1100 cb500 cb350 rt 200 xs 650
    Suggest if you use this method to tap the new bolt/post before welding; maybe get someone with a metal lathe to drill it and do it for you nice and tidy. Then anti- seize compound on the new threads and put a bolt in there to protect the new threads until you are finished.
  4. PC. Husqvarna
    AA Class

    Location:
    Beaverton, OR
    Husqvarna Motorcycle:
    CR165 & CR144
    Other Motorcycles:
    KTM500
    Nice idea! I'm sure a grade 5 bolt is much cheaper and easier to find than an actual post. And since its hidden under the tank it doesn't matter what it looks like.

    Now I just gotta get off my ass and do it!
    juicypips likes this.
  5. flyingbob Administrator

    Location:
    USA
    Husqvarna Motorcycle:
    01&02WR360_02WR250_02CR250_12WB165
    Other Motorcycles:
    01 VOR400_07 TM450_22 GG250_07 Tuono
    Might be easier to cut a bolt off, weld it to the frame and use a stepped washer/bushing to locate the tank. Screw a nut on and call it good.
    PC. and sabortooth like this.
  6. PC. Husqvarna
    AA Class

    Location:
    Beaverton, OR
    Husqvarna Motorcycle:
    CR165 & CR144
    Other Motorcycles:
    KTM500
    Nice call! That would actually take some abuse too.
    Either method would be dirt cheap :cheers: