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I have a 2020 Roadster that I want to set up as a lightweight cruiser. As a part of that I want to get a 4.5 gallon Sportster tank to replace the 3.3 that I have now. Is this a simple bolt-off/bolt-on exchange, or are the mounting points different on the Roadster? Same question for the seat -- if I put the 4.5 gallon tank on, will a Sportster seat designed for that size tank work on the Roadster? I'd really like to double my distance between gas stops if I'm going somewhere.
You will need to trim the seat a bit or get another seat. A few people have put 4.5 g tanks on 16+ Roadsters, Crusty at xlforum for one. Be aware the the actual capacity may not be 4.5 gallons, on my own 08 Roadster the bike will stumble if I accelerate and I've used about 3.5 gallons due to the EFI pump sucking air and I've read of some others with the same experience. A theory I read somewhere (that makes sense) is that when HD converted the tank to EFI in 2007 that they did not account for the difference in capacity due to the pump, filter, pickup vs. petcock etc.
Last edited by 08xl1200r; Jan 25, 2023 at 12:18 PM.
The XL1200CX Roadster seat will need to be changed when installing a 4.5 gallon fuel tank, the seat touches the rear of the stock 3.3 gallon tank and the 4.5 gallon tank besides being wider it is also longer than the stock tank. See the images below of an XL1200CX and an XL1200CA.
The pump doesn't displace a gallon of petrol. Although some seem to have pickup problems there is a similar number who have almost emptied their tanks without any issue at all. I don't know what the problem is. I have used more than 3.5 gallons but maybe when the fuel gets low and one is looking for a petrol station "getting on it" is a style not employed.
Thanks to all, I think I have what I need. I thought the frame was the same, but I wasn't sure, and I didn't want to launch this project it the parts weren't going to fit. I plan to have an engine built with a bit more punch. Along with that I am going to put the 4.5g tank on (so I wanted to confirm that it would fit my frame without having to do a crapload of custom work). And yeah, I understand that I will need to change the seat, but Corbin, for example, makes it clear which seats work with a 4.5g Sporty, and which ones don't. 100+ HP, with 4.5g of gas, and a comfortable touring seat should be a good start on a light cruiser. Still gotta figure out the bags, and the rear suspension, but it is starting to look doable. Again, thanks for the input!
Last edited by wlwoodruff; Jan 25, 2023 at 05:53 PM.
It is unfortunate that with HD stopping production they also stopped making lots of bags for Sportsters. Mine came with hard bags but are not very big. HD used to make some nice leather bags that held more and designed them to take more weight.
Thanks to all, I think I have what I need. I thought the frame was the same, but I wasn't sure, and I didn't want to launch this project it the parts weren't going to fit. I plan to have an engine built with a bit more punch. Along with that I am going to put the 4.5g tank on (so I wanted to confirm that it would fit my frame without having to do a crapload of custom work). And yeah, I understand that I will need to change the seat, but Corbin, for example, makes it clear which seats work with a 4.5g Sporty, and which ones don't. 100+ HP, with 4.5g of gas, and a comfortable touring seat should be a good start on a light cruiser. Still gotta figure out the bags, and the rear suspension, but it is starting to look doable. Again, thanks for the input!
It looks like you bought the wrong Sportster model in the first place for your needs, the XL1200CX was introduced as H-D's Cafe' Racer style Sportster, the XL1200T was their touring Sportster model.
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Bigger tank for 2020 Roadster
