Headless screws - can I salvage my gas tank?

1909 Views 15 Replies 5 Participants Last post by rxf610, Feb 3, 2014

MtnMan

Discussion Starter · Jan 5, 2014

Hello,

I finished the first season on my new to me 1998 TL1000S and when the days got colder I noticed a gasoline smell in my garage. I found that it came from the bottom of the gas tank of the Suzuki.

When I took a closer look I saw that two of the screws that attach the fuel pump assembly to the tank were seemingly missing. I ordered a new gasket, removed the tank and when I removed the fuel pump assembly I saw that the two "missing" screws had their heads stripped off :banghead

The picture shows the screw that has practically no protruding part, the other one has very little of the threads protruding, but probably not enough to grab it with anything. I used a small chisel with the latter screw shaft but was not able to make it turn. Am I screwed? :O

I thought about carefully grinding a small slot into the shaft but I want to avoid damaging the sheet metal around the screw shaft and I am also a little nervous creating sparks with all the gasoline fumes.

How can I get these screws out?

Any hints would be much appreciated!

Greetings from wintry Colorado,
Armin

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Felipe

· #2 · Jan 5, 2014

Can you grab ahold of it from the other side, inside the tank?
Do you know if the tank recal has been done? If not you may be in for a new tank. Check that first. My 97 TLS got a brand new tank just 2 or 3 months ago. I would check that first. Apparently the bottom looks different. If u want I can take a picture of my new post recall tank. If yours looks different chances are u won the suzuki recall lottery. If not, sorry play again. :O
If it's been recalled already try and see if you can maybe get ahold of the areas from inside the tank. If u can turn them with some needle nose pliers or whatever till they come out inside the tank. Try that and let us know.

The Ring-In

· #3 · Jan 5, 2014

the threads are not accessible from in the tank and its not a recall model.

the threads can be drilled out carefully. take the tank to a radiator repairer and they can bronze fill the holes for you. then you can file the surface smooth and drill and retap the holes in to the correct size.

alternately you can buy some 5mm threaded rod and cut it to 3/4in lengths. the radiator shop can silver solder these into the holes and you can use nuts to hold the pump in.

MtnMan

Discussion Starter · #4 · Jan 5, 2014

Thank you for the recommendations!

My bike was manufactured in 10/97 and it looks like the tank recall was performed on my bike: The tank has a "7-01" sticker and there is an "OK" sticker on the right side of the frame. Also the tank support brackets are installed.

Here is a link to the Service bulletin that describes in minute detail what the dealerships have to do:

http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/ACM53647/RC-98V133-NN.pdf This is a 146 page document so it may take a few moments to load.

So I will not get a new tank from Suzuki and have to get the existing tank fixed or a new tank. My tank has a medium sized dent and the paint does not look great anymore so I am considering getting a new tank.

There are NOS tanks on eBay for ~$500, and it looks like they are the modified tanks after the recall, will try to confirm. It looks like the support brackets are included with the tank, so this might indicate that this is a modified (post-recall) tank.

http://www.ebay.com/itm/GENUINE-NOS...Parts_Accessories&hash=item53edd8b4ca&vxp=mtr

Thanks again for your help!
Armin

tiller4me

· #5 · Jan 5, 2014

A recall tank will have an 'X' stamped on the bottom of the tank. If it is of any help, I would advise watching and waiting for a bit before you bale off for a new tank. There are several from time to time that are in like new condition for way less than new. I bought 2 tanks for less than $100 each. Neither had rust nor dents and were 'X' stamped. I am currently waiting for my replacement tank to arrive. If it arrives fairly soon, (doesn't look promising), and you are still in the market, I will give you a good deal on one of mine.

MtnMan

Discussion Starter · #6 · Jan 5, 2014

Thank you, tiller4me, I appreciate it!

I looked at my tank, but did not see the 'X', may have overlooked it. Where on the bottom of the tank would it be and how big is it?

Armin

tiller4me

· #7 · Jan 5, 2014

It is a BIG X stamped in the metal bottom. If it is there you can't miss it. You might try going to your local dealer and have him run your serial number to see if all recalls have been done. I am not sure if the recall affected '98 or not. Someone else may chime in soon with that info.

MtnMan

Discussion Starter · #8 · Jan 5, 2014

tiller4me said:
It is a BIG X stamped in the metal bottom. If it is there you can't miss it. You might try going to your local dealer and have him run your serial number to see if all recalls have been done. I am not sure if the recall affected '98 or not. Someone else may chime in soon with that info.

Thank you. According to the document from the National Highway Traffic Safety Administration (see link in posting above) ALL 1997 and 1998 TL1000S bikes are affected:

Armin

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The Ring-In

· #9 · Jan 5, 2014

10/97

is technically the 98 model.

the change over is in october for suzuki bike models

tiller4me

· #10 · Jan 5, 2014

Then you really need to check into it. If yours hasn't had the recall for the tank done, you will be eligible to receive a new tank. Availability will vary from color to color. I have been waiting for over 6 months for a green, but I have been assured it is still on backorder from Zook.

If one is not available from Suzuki soon, I would still keep an eye out for a good, cheap used one so you won't be rideless, or follow Stu's advice on the 5mm rod.

What color is your bike?

Felipe

· #11 · Jan 6, 2014

Apparently red is not a problem to get probably because so many were red. I imagine green would be a pain to get.
Here's what a recalled tank looks like.:

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MtnMan

Discussion Starter · #12 · Jan 7, 2014

Felipe said:
Apparently red is not a problem to get probably because so many were red. I imagine green would be a pain to get.
Here's what a recalled tank looks like.:

This (large star shaped character) is what you mean by "stamped with a 'X'"? My tank has this large star, so the recall was definitively performed on my bike.

My bike is black. I checked with two eBay vendors who offer NOS tanks. The tanks they offer look black but it turned out that both of them are dark green, good thing I checked, nothing is easy!

Thanks again for all your help,
Armin

tiller4me

· #13 · Jan 7, 2014

This looks to be a black one in Italy: http://www.ebay.com/itm/Fuel-Tank-S...Parts_Accessories&hash=item27d28d2df4&vxp=mtr

Taking offers

MtnMan

Discussion Starter · #14 · Feb 3, 2014

Thanks again for your help!

I was finally able to get the headless screws out with a "Grabit Pro" extractor:

It was amazingly easy.

Greetings from wintry Colorado,
Armin

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Felipe

· #15 · Feb 3, 2014

Nice, always wondered if those actually work. Now I know.

rxf610

· #16 · Feb 3, 2014

Felipe said:
Nice, always wondered if those actually work. Now I know.

That's the extractor I used in my thread (thread.... :laugh)...

Got out the bolt on my frame that gave me such a headache.

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