<p>In the two-wheeler industry, shaker testing is used to simulate real-world conditions and identify potential fatigue failures in components during vehicle development. This paper focuses on the design and failure analysis of a motorbike fuel tank assembly during shaker test. A hairline crack was observed near a spot weld between the tank bottom and rear support bracket at 35% of the target fatigue life. Possible causes of failures identified using a fishbone diagram and finite element analysis (FEA) revealed design flaws in the rear support bracket and spot welds, coupled with assembly issues. For further investigations on the design, a finite element analysis (FEA) model of fuel tank assembly was developed. Using the acceleration input loads measured from the test track, shaker test and FEA simulation have been performed. FEA output responses showed high stress amplitudes near the spot weld, correlating with the physical failure. Design modifications were proposed in the support brackets to improve the stiffness, and rubber cushion with variable stiffness is added to accommodate the tolerance variation. The modified design resulted in a substantial 62% stress reduction in FEA simulation. In addition, actual fatigue life testing also demonstrated an increase of more than 2X of target durability life in testing. The successful implementation of countermeasure design, validated through shaker testing and FEA, highlights the importance of virtual design verification before physical validation.</p>