5 gal tank

[Tonyb65]

I just received the cast dash and mount plate kit today but there wasn't any installation instructions with it. Does anyone know where I can get instructions for this kit or can assist me with this. I looked online nothing on you tube and nothing in the HD softail manual. Any assistance with this would be greatly appreciated.

[Tonyb65]

Faster project moving right along. Received the dash, speedometer, ignition switch dash mount plate kit and hardware. This is a test fit of the base mount plate, speedometer and ignition switch. Without installation instructions thought I would do my best to figure out the basic stuff. So did a test fit of the components unfortunately the dash did not fit so I have to return it to J&P cycles

Die cast dash plate mount


Die cast dash plate mount, FL style speedometer and ignition switch


side view of assembly


Pulled back for an oblique angle

[Tonyb65]

Right tank set to where it needs to be for final assembly. Need to Fab the mount brackets and then onto fuel lines and wiring.

[Tonyb65]

Got the final fabrication of the tank mounts finished and installed. Needs some touch up paint, then final tank assembly, ignition and light wiring, then fuel lines.

[Tonyb65]

Got the mock up and fabrication completed. I mounted the tanks in place Today. I think this is going to look great when finished.

[TheBreeze]

I realize this an old thread but I just bought a 5gal tank that came off a 95 Sporty to replace my stock small tank on my 2000 883 Hugger.
I've got a few questions since I'm definitely new to Sportsters and have never done an aftermarket tank swap before. On my stock tank there's a small hose, bottom right rear of tank, I'm gonna assume is the O2 sensor line? On the new larger tank it's not present but there are 2 small nipples on either side towards the front of the tank which I'm also gonna assume is for a vent line, altho def not sure?

My main question is can I or do I have to have the missing sensor installed on the new tank? Also I don't see any other lines coming from my old tank other than the main fuel line and what I'm assuming is the O2 sensor line. I know if I don't hook up the O2 line the bike won't run correctly, especially in a decel mode. Do most shops install these lines/modules, especially since aftermarket tanks are becoming more popular?

Sorry for the newbie questions, the only bike I ever owned, stripped down to the bare frame and totally rebuilt, altho 100% stock, was my 76 FXE Superglide. It's been over 20yrs since I owned or worked on anything mechanical like this.
This 2000 Hugger of mine is going to be my personal custom build, whether I can do most of the work or not and want it to come out just the way I want it...perfect. Thanks for the help and tips guys...

[sportsterpaul]

5 gallon tanks have never been stock on Sportsters, is the one off the 1995 a two piece tank and are there gas caps on each tank? It was popular, and continues to be, putting gas tanks off of Big Twins onto Sporty’s, for looks and or extended range. I would guess if the tanks are two piece then the nipples at the front are gas interconnections allowing one tank to fill from the other.

[ParrotHead]

Originally Posted by TheBreeze

I realize this an old thread but I just bought a 5gal tank that came off a 95 Sporty to replace my stock small tank on my 2000 883 Hugger.
I've got a few questions since I'm definitely new to Sportsters and have never done an aftermarket tank swap before. On my stock tank there's a small hose, bottom right rear of tank, I'm gonna assume is the O2 sensor line? On the new larger tank it's not present but there are 2 small nipples on either side towards the front of the tank which I'm also gonna assume is for a vent line, altho def not sure?

My main question is can I or do I have to have the missing sensor installed on the new tank? Also I don't see any other lines coming from my old tank other than the main fuel line and what I'm assuming is the O2 sensor line. I know if I don't hook up the O2 line the bike won't run correctly, especially in a decel mode. Do most shops install these lines/modules, especially since aftermarket tanks are becoming more popular?

Sorry for the newbie questions, the only bike I ever owned, stripped down to the bare frame and totally rebuilt, altho 100% stock, was my 76 FXE Superglide. It's been over 20yrs since I owned or worked on anything mechanical like this.
This 2000 Hugger of mine is going to be my personal custom build, whether I can do most of the work or not and want it to come out just the way I want it...perfect. Thanks for the help and tips guys...

My guess is the small hose on the 2000 tank is an overflow line, however if you can post a picture it may help identify it.

[spoon]

The small hose is fuel overflow. No O2 sensor on a 2000.