Yamaha XTZ750 Super Ténéré

Bravo. Wider is generally better and you can't go wrong with Renthal.

Good work, I love the the paint scheme.

On the tank, looks like it's been brazed already (or is that brass color just funny light in the photo)? If so, you won't be able to weld around there easily unless all that is removed.

I'd blast the whole area clean first for a proper look. If there's braze present, it might be easiest to fill the whole area behind the captive nut with more. If not, I'd cut the little bracket off and weld the hole shut, then just tack it back on. You might even be able to get someone to tig it with a lot of stick out and the gas turned up without cutting the bracket. Looks like you could get the tungsten in there.

Cutting a hatch seems like more work.

Weirdly the brazing looks like it's from the factory? I was hoping to avoid removing the bracket so there wouldn't be any alignment issues with the bodywork going back on after but maybe getting some braze in there to fill the hole would be the easiest solution alright?
I'll get it stripped back for a better look first of all and go from there I suppose?

Yeah, strip it back and braze it up I reckon. Easy job once the tank is purged.

I've just been having a chat about this with my mate who worked in the bike trade for years.
Here's the plan...

Fairing bolt is M6 as far as I can remember (I'm away for work at the moment so need to double check when I get home, could be M5).

I'll strip paint, clean all around the area as best I can with Dremel.

Get a 6mm bolt, cut it down to c.10mm length and then flare the end enough for it to no longer fit through a 6mm hole.

Pop it into the hole and solder over it and it should do the trick with minimal messing, shouldn't need to upset the existing brazing as solder will melt at lower temperature than the braze.

It seems like a slightly unrefined solution to me to be honest but I've got background in plumbing so I'm well used to soldering and if it gets the job done then who am I to argue!

I'll pressure test the tank with some air afterwards and if it passes that I think that's one job done...

I feel like I've missed why you're doing this. Didn't you say the existing repair is functional?

Yeah the existing repair was solving the issue of the leak but it rendered the fairing mounting point unusable so I was missing one fairing mounting bolt.

Update?

... a month later I've gotten the tank stripped. Awful progress but better than none at least...

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