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  #1  
Old 4th May 2012
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Default 4.5 gallon tank swap on 2011 Sportster 48

any advice from someone who has done this particular swap? From what I understand it's just a straight swap........my tank arrives later today....




Last edited by Folkie; 10th May 2012 at 22:14.. Reason: Improved layout to reduce width
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this might help

http://xlforum.net/forums/s....php?t=1415916
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Old 4th May 2012
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Quote:
Originally Posted by FiremanTx View Post
+1 - that should be all you need. Switch fuel pump and lines to new tank and remount.
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Old 4th May 2012
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Arrow A few tips...

I swapped the 3.3g on my '06 for the 4.5g.
It was an easy bolt on.
I had to modify my OEM seat cos the 4.5 is longer, but you may be OK what with that gap already there.
Here are a few DIY tips re the swap procedure (some of the technical details may be different on your '11; read your Service Manual):

a) Empty the peanut before you remove it! Many XL owners have had a tank with gas sloshing around in it tumble out of their grasp and hit the shop floor like a hard-boiled egg

b) Mind the hoses attached to the underside of the tank:
> the fuel line emerging from the petcock
> the vent (overflow) hose
> the nasty vapors hose

c) You'll prolly move your old petcock to the new tank. Take advantage of this opportunity to clean the filter before re-installing petcock.

d) Your new tank will ride lower than your peanut, so accessing wiring and hoses underneath the tank will be more difficult.

e) Take your time installing the 4.5. Those 'ears' holding the front in place can be a bit of a hassle. Patience. You may have to try several times before it goes on correctly.

f) Remember to reconnect all those hoses! Count them to be sure. If you overlook the vapor hose your engine will run crappy.

g) CHECK FOR LEAKS! Any hint of gas escaping? You don't want that.
When you restart, listen for air leaks. Remember to open the petcock valve. Oh, and remember to put some gas in the tank. Don't laugh--people have done this, then start thinking their ignition needs work.

h) What plans do you have for that tiny old tank?
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Old 5th May 2012
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The stock 48 seat is designed for the 4.5 gal tank spacing. If your seat is not designed for the 4.5 gal tank, you may not have enough room in there. The vent hose on the 2.1 connects in a different spot than the 3.3 or the 4.5 so it may require a bit of cutting to work right.

Nothing against the previous post but a lot of that doesn't apply to EFI. There is no vapor hose nor is there a petcock. There is a push-to-connect style fuel quick disconnection joint and there is an electrical plug for the fuel sending unit. I haven't watched the video by screw loose dan but I would be willing to bet that it is all covered. Also, the tunnel in my 2.1 is much deeper than on my 3.3 so the larger capacity tank actually sits higher on the spine. Never mocked up a 4.5 on it though so I can't compare that.

Some people (like the OEM) recommend always replacing the fuel sending unit gasket. I didn't and it works fine so far.

Once you get everything bolted back on, slowly and carefully move the handlebars from lock to lock and make sure you're not hitting the tank with the mirrors.

That's all I can think of for now.
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Old 5th May 2012
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If you didn't already swap the tanks over, it should be fairly straight forward. Only two things I can think of might be the vent hose mentioned by lostNdallas and the seat if you don't have the original. Off the top of my head, I believe the fuel line for the larger tanks is actually a different part number, but I know plenty of folks have swapped tanks without any issue using their original fuel line.

FYI, below are pictures are what the tank looks like with the fuel pump removed and a separate picture of the fuel pump.



(that green bit around the bottom is the gasket lostNdallas mentions.)
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Last edited by Screw Loose Dan; 21st February 2018 at 19:29.. Reason: Updating link to pictures
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Default swap has been done......

thanks for all the advice.........
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looks sharp, came out nice!
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Nice. It's amazing how a tank can completely change the look. I guess I was worrying about mirror strikes for nothing.
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