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Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders Discuss Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders problems, advice, and/or how tos.

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  #1  
Old 17th August 2019
broknluck broknluck is offline
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Default New Gas Tank or Cat Litter Jug.

I am looking for a new Gas Tank or Fuel Cell for my 1999 Carberated Sportster.Im considering a larger than stock size;But I found when said Something Fits does not always mean Everything Fits or Works.Many tanks are without the vent tube thing on the right side.My other concern is correct Petcock Hole Size??? Even with the after market King Tank I see some fitting issues. Any suggestions on a bolt on tank.I once put a Polyurethine ? tank on a racing bike many years ago.Id rather hang a plastic jug on it than waste money on a non fitting head ache.
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  #2  
Old 17th August 2019
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Maxeffort Maxeffort is offline
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I've been looking too. The aftermarket 4.1 gallon tank requires a vented cap.
If you just need a 3.3 king tank, there are plenty of good used tanks for sale. Maybe even in the same factory color.
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Old 17th August 2019
broknluck broknluck is offline
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Quote:
Originally Posted by Maxeffort View Post
I've been looking too. The aftermarket 4.1 gallon tank requires a vented cap.
If you just need a 3.3 king tank, there are plenty of good used tanks for sale. Maybe even in the same factory color.
Ill get a new tank .
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  #4  
Old 19th August 2019
broknluck broknluck is offline
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I got a Porkster 4.2 tank,it fits the 1999 Sportster just fine but stock gas caps do not fit.

Last edited by broknluck; 3rd September 2019 at 10:08..
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  #5  
Old 24th August 2019
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ron521 ron521 is offline
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I can tell you that the "V-factor Legacy Gas Tank 81062" on the Dennis Kirk website (https://www.denniskirk.com/v-factor/...prd/189122.sku)
did NOT work on my 1991 XLH.

Specifically, without the petcock installed, the tank would fit fine on the frame, and the mounting holes would line up properly front and rear. However, the bungs projected far enough out that the factory petcock could not be installed on either side. If installed on the right, the petcock hit the top of the carb diaphram cover. If installed on the left, the petcock hit the top motor mount. With the petcock installed on either side, the rear tank mount could not be made to line up with the holes in the frame.

Looking at other petcocks in the DK website, nothing appeared to be significantly shorter than what I had, and I didn't really want to buy something else to make it work when the tank was advertised on Dennis Kirk's page as "Exact Fit".

It really is a shame, because without the petcock installed, I liked the lines of the tank itself (something like a cross between the standard peanut tank and an old Triumph tank) as well as the way the tank sat low over the engine, and blended in with the lines of the frame and the seat. Everything LOOKED like it was designed to work together, and the tank had a very useful capacity of almost 4 gallons...except for the petcock issue. I could make it work with a tank lift, but that would break the lines and spoil the appearance.

So...I'm also looking for other alternatives, and will be following this thread to see what others come up with.
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  #6  
Old 3rd September 2019
broknluck broknluck is offline
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Quote:
Originally Posted by ron521 View Post
I can tell you that the "V-factor Legacy Gas Tank 81062" on the Dennis Kirk website (https://www.denniskirk.com/v-factor/...prd/189122.sku)
did NOT work on my 1991 XLH.

Specifically, without the petcock installed, the tank would fit fine on the frame, and the mounting holes would line up properly front and rear. However, the bungs projected far enough out that the factory petcock could not be installed on either side. If installed on the right, the petcock hit the top of the carb diaphram cover. If installed on the left, the petcock hit the top motor mount. With the petcock installed on either side, the rear tank mount could not be made to line up with the holes in the frame.

Looking at other petcocks in the DK website, nothing appeared to be significantly shorter than what I had, and I didn't really want to buy something else to make it work when the tank was advertised on Dennis Kirk's page as "Exact Fit".

It really is a shame, because without the petcock installed, I liked the lines of the tank itself (something like a cross between the standard peanut tank and an old Triumph tank) as well as the way the tank sat low over the engine, and blended in with the lines of the frame and the seat. Everything LOOKED like it was designed to work together, and the tank had a very useful capacity of almost 4 gallons...except for the petcock issue. I could make it work with a tank lift, but that would break the lines and spoil the appearance.

So...I'm also looking for other alternatives, and will be following this thread to see what others come up with.
The 4.2 Porster fits my 99 sportster very well .Also Ive seen a metal hold down strap set up if your tank if it dont line up with the bolts
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  #7  
Old 10th October 2019
farmall farmall is offline
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Quote:
Originally Posted by ron521 View Post
I can tell you that the "V-factor Legacy Gas Tank 81062" on the Dennis Kirk website (https://www.denniskirk.com/v-factor/...prd/189122.sku)
did NOT work on my 1991 XLH.
Bungs are cheap so if you weren't able to return the tank or like the lines you could have a local weldor install one where you like and grind the existing bungs near flush then weld them shut. A bit of clean round bar or cutoff bolt makes a tidy plug. Tack plug to weld filler wire for a handle, insert plug into what's left of the old bung, tack then finish weld and smooth with flap disc. A step drill but doesn't grab sheet metal if you want to drill it yourself and step bits are insanely useful to own. Blow out tank with compressed air to ensure no crumbs.

It's simple, easy work. Show your weldor this post.
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