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Installing 6 gallon gas tank on Sportster 883

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Old 03-31-2013, 06:16 AM
eagle--rider eagle--rider is offline
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Default Installing 6 gallon gas tank on Sportster 883

Hi,

I hate having to stop for gas so often so I am wanting to install an inexpensive 6 gallon gas tank (preferably a 1 piece gas tank) onto my 1991 Sportster Deluxe 883.

Has anybody done this?

If you have done this, will you please post instructions and advise on which gas tank to buy and how to do it and what modifications I have to do if I have to use a 2 piece gas tank?

Also I am concerned about the handlebars hitting the gas tank any advise on this problem?

Thank you, eagle--rider.
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Old 03-31-2013, 07:24 AM
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grbrown grbrown is offline
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Hi from the UK and welcome to HDF. You don't want a lot do you?! I have a 6 gallon tank on my Glide, off a recent model, so have done it, but that won't help you much. In addition you may not find a 6 gallon Sporty tank, although there are plenty of 5 gallon ones, both one piece and 2-piece.

If you use the 'Search' in the blue bar above, go to advanced search, type in '6 gallon' and select Sportster Models you will get some background reading, which will provide some help that may help you narrow down your quest.
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Old 03-31-2013, 07:27 AM
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Theres a decent thread over on XLForums on something like this.
A guy over there put a SuperGlide tank on a Sportster.
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Old 03-31-2013, 07:50 AM
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DavidStiebel DavidStiebel is offline
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Hey, I'd suggest the 5 gallon tank found on most 1200's, it works well for me as I gotta stretch and use the head from time to time.

.
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Old 03-31-2013, 01:14 PM
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I think JP cycles has a kit that will let you mount the Flat side tanks to your Sportster. Don't know about a 6 gallon 1 piece tank. You could mod your frame to do it though.
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Old 03-31-2013, 01:47 PM
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If you're changing from the 3.2 gal to the 4.5 gal, don't forget you need a different seat.
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Old 03-31-2013, 02:23 PM
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My 4.5Gal. tank on my 08 1200C will get me about 250 miles on the super slab. Trust me you want a 1/2 hour brake after that many miles.
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Old 03-31-2013, 04:58 PM
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As the others have said, I'd look at the carb version of the 4.5 gal tank. I'm not sure if it would be a straight replacement since your bike is a '91. You might have to fab up a bracket or something for installation.

At the worst gas mileage you'll get 140 miles in urban traffic between fills with 1/2 gal left in the tank. On the slab, well over 175 miles and probably closer to 200. On average I'd say 150 miles. That's more than enough except for even the least populated areas.

One thing you won't have to worry about with the 4.5 tank is most handlebar clearance.
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Old 04-26-2013, 01:29 AM
eagle--rider eagle--rider is offline
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Hi Guys and Gals,

I appreciate the replies to my questions. Thank you all.

I will check out the other Forums Threads on the subject of placing a larger fuel tank on a Sportster.

As of now I have a 4.2 gallon fuel tank on my bike.

And my bike looks more like a "Heritage Softail" than your run of the mill "Sportster"

Thank you all for your advise.

eagle--rider
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Old 04-26-2013, 05:39 PM
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Quote:
Originally Posted by eagle--rider View Post
Hi,

I hate having to stop for gas so often so I am wanting to install an inexpensive 6 gallon gas tank (preferably a 1 piece gas tank) onto my 1991 Sportster Deluxe 883.

Has anybody done this?

If you have done this, will you please post instructions and advise on which gas tank to buy and how to do it and what modifications I have to do if I have to use a 2 piece gas tank?

Also I am concerned about the handlebars hitting the gas tank any advise on this problem?

Thank you, eagle--rider.
A friend of mine has a 6.2 gallon tank from a CVO Road Glide on his XR1200X. It's his Hoka Hey Challenge bike. Doc's H-D did the work.

Ron Pogue @ Vision Metalwerks or Rene @ Mercury Moto could make a custom tank for you.
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