I've been looking around to do some upgrades on my sportster but I can't find an easy solution. I use my Harley to commute and I need a bigger tank. I don't have all the money in the world so I'm looking for the most cost efficient way. I see that there is a 4.5 gallon tank for a 2004 sportster custom but it says it's not compatible. Why? Are there any other bigger tanks I can use in the Harley line that is bolt on? Any help would be appreciated. Thanks in advance.

 

What year bike do you have? Usually the main difference on the tank is if its a petcock or EFI. I bought both of my tanks for my 48 on ebay, first a 3.3, then the 4.5. With patience you should be able to find a tank for your bike. They should be interchangeable. I'd also ask my dealership parts guy the part number you should be looking for, he should be able to tell you.

 

It's a 2004. I went JPcycles, revzilla, eBay and Amazon and the 4.5 aren't compatible. Is it because they never made it for xl883 standard? I would think its the same exact frame. I'm just not sure if there is some type of difference with the fuel pump, some other items that would obstruct installation or something along those lines that wouldn't make it work. I understand I'm not an expert so I except the possibility that everything I'm saying sounds stupid. Lol

 

Hi from the UK and welcome to HDF. Your starting point for reference info should be H-D and you can get clues on compatibility by using an on-line parts website.

You shouldn't have too much difficulty finding a suitable tank. The only reason I can think why a larger tank might be described as not compatible for your model is that it is longer than your current tank and you may need a shorter seat.

This Ebay tank from a Custom, #231824116453, is suitable, as you can see, although a bit knocked about. The ad also spells out things you can benefit from when looking around. If you keep an eye on Ebay and are patient you should be able to come up trumps. I bought a secondhand 6 gallon Glide tank, with a small dent, for less than 100 dollars.

Taking the hint from that ad, if you want a new aftermarket tank, look for ones that fit 2004-2007 bikes. After that H-D went to EFI.

 

An '04-'06 4.5 glln tank will fit. Those years are carb'ed, rubber-mount frames. The only hindrance is the seat. The saddles for a 4.5 tank are a little shorter than the saddles for the 3.3 tank. You can peel back the front of your existing seat, trim the seat's foam and re-staple the cover. Or, get a different saddle designed for the 4.5. Other than that, a factory 4.5 tank (2004-2006) will bolt directly on with zero modification. Sportsters went to fuel infected in 2007, not 2008. Adapter plates, to allow fitment of a fuel petcock (carb'ed bike) in a fuel injected tank (2007-up) are available through aftermarket sources.
Seat fitment:
https://www.hdforums.com/forum/sport...y-saddles.html

 

If you've got the 3.3 gallon tank as stock, the larger tanks will require a different seat since the larger tanks are too long for the seat on a 3.3 gallon bike.

 

Read POST 5 and you'll find all the information you need.

 

The 6 gall tank I mentioned earlier was EFI. I used a stock EFI mounting plate, with nothing on it, as a blanking plate, plus a Pingel gas tap and adapter. The adapter is necessary as the thread in the tank doesn't match the thread on the tap.

 

I've got this tank coming for my wifes 883, which came with the peanut tank like yours-only difference with hers is EFI. So yes you will be able to run a 4.5gal tank with seat mod or replacement. Harley even sells an installation kit for a custom tank install(harley 4.5) and the instructions mention need to run a seat designed for the swap.

I'm waiting for her to design a custom seat on the mustang seat web site designed to work with the 4.5gal tank. I've ordered these tank nameplates to replace the ones currently on the tank.

That will be the easy mod-next mod is to install FL softail front end and 16x3 wheel up front and some led sled foot boards-it'll be a sportster slim?(FAT maybe).

 

That tank looks good and the emblems. That looks like a good size tank. I was scared that a 4.5 would be absurdly unproportional.