I have a '97 Sportster 1200 Custom. I noticed that the gas tank was making an annoying vibrating sound. Upon removing the gas tank, I noticed that the mounting stud weld on the frame for the rear of the tank was broke. Is this commom? Is there more than one way to fix it? I have a Millermatic 175 MIG welder and was going to reweld the broken welds. There are several wires in the area so I will have to cut some of the zip ties and shield the wires. In the past when I have welded on trucks/cars I have removed the battery as a precaution to wrecking electrical components and have had no problems. Is that same precaution adequate on my Sportster, or do I need to do anything else? I would appreciate hearing from anybody that has had to solve the same problem. Thank you.

 

Always a good idea to protect you electricals, and shield wires. Id just be worried about welding around the gas. lol

Shouldn't have any problems IMO.

 

When I weld (or grind) on a bike that is basically still complete I use aluminum foil to protect anything I don't want hit with sparks.

Also, I sand down to bare metal approx. 1" around the weld area. It's easier to touch up or paint a raw area than a heat-bubbled powdercoated area.

Unhook the negative cable atleast.

 

I believe that when pro welders weld on any sort of tank holding anything flammable they give it some sort of bath that cleans out all the residual stuff. I would probably take it in and let someone else do it.

 

Steverinno it sounds like ya got it made, seeing as its only little baby welds it should be alright.
As a fellow welder i've seen shop cranes n forklifts get fried internally from welders grounding running through it so i haven't ever personally welded on a sportster without removing the motor too BUT thats just me, countless guys have TIG welded on hardtails with motors in with no reported problems but i'll never know if it does no harm cuz after i personally seen shop cranes n forklifts fried internally from welders grounding i'll never ground my engine but thats just me

 

yeah you can weld it up...haven't heard of this being comon though. whenever i weld i just make sure to cover my engine up good...especially with a mig...ya don't want molten metal falling on your alluminum cylender....that would suck!!