2004 Roadster Tank Conversion

[Kentucky]

Ok folks it's time to spend some money on my crashed bike and make this 1200R look way different. The original bike had the 3.3 gallon tank painted Smokey gold with the cream colored band and Harley-Davison logo. Harley wants $522 for the tank. Now it gets interesting. I can get the Smokey gold 4.5 gallon tank direct from Harley for $525 plus $15 for the mounting hardware and it has a vivid black band around the sides that would work very well with the current look. In order to make the tank swap I need a new 1200C seat. I found a new Sportster deluxe seat for 169.95 from Harley. So, the entire conversion would cost $709.95 plus tax. Has anyone made this conversion and are you satisfied with the bikes new look?

The only problem I can see is the color of the tank shown in the pictures. It looks darker and more like the gold/black that I have seen on the touring bikes. Maybe it's just the photograph.....

[xena]

A tip: Order your parts from Zanotti Motors and you should
pay approx. 20 % less. Get a seat on ebay or even
check our classified section. You can do better than
that 709 price tag - if you want to that is.

[johnkiddier]

I've just fitted a 1200c tank to my 06 883 standard.

First, you do not need any additional hardware at all. The bolts from your existing tank swap straight over. The only thing that you might want is the little plastic cover on the forward tank tabs. It seems a lot of money for the sticky back plastic and it's not necessary anyway. Petcock etc just swaps straight over without problems. You'll end up with a 2.5 litre reserve using the petcock from your standard tank.

As for the seat....I'm a cheapskate so I simply modified it to fit. Take the seat off, flip it over and you'll see the cover is simply stapled on. Remove the staples at the fornt and peel back the cover. Now using a combination of bread knife and hacksaw cut about 1/2" from the front plastic lip and reshape the foam to fit. Then simply staple the cover back on. Easiest thing in the world. I couldn't believe how simple it was.

Good luck.

edited for teribiul speling

[Speedy818]

Originally Posted by Kentucky

Ok folks it's time to spend some money on my crashed bike and make this 1200R look way different. The original bike had the 3.3 gallon tank painted Smokey gold with the cream colored band and Harley-Davison logo. Harley wants $522 for the tank. Now it gets interesting. I can get the Smokey gold 4.5 gallon tank direct from Harley for $525 plus $15 for the mounting hardware and it has a vivid black band around the sides that would work very well with the current look. In order to make the tank swap I need a new 1200C seat. I found a new Sportster deluxe seat for 169.95 from Harley. So, the entire conversion would cost $709.95 plus tax. Has anyone made this conversion and are you satisfied with the bikes new look?

The only problem I can see is the color of the tank shown in the pictures. It looks darker and more like the gold/black that I have seen on the touring bikes. Maybe it's just the photograph.....

You don't even need the new seat. Just pull the staples out from under the cover, pull back the cover, lift up the foam and dremel away an inch or two of black plastic. When you find the right amount, trim the foam with an X-acto knife, tuck the cover around & staple - takes all of ten minutes.

Big Tank on a Roadster is Big fun!

EDIT: Oh - I suppose I should type faster - someone beat me too it... Thanks John!

[Kentucky]

Ok folks, this is were I am at. I ordered the tank and a new all leather badlander seat from Zanotti this morning. It's not that I couldn't mod the seat to fit but more the fact I have hated that seat from day 1 and not because of how it felt but more because it looked like crap when compared to the 04-05 1200C. The other reason is simple, I am so friggen anal about this damn bike and my others that I want it to look factory perfect with every little washer and bushing that could possibly be picked up by any inspector. I know this sounds crazy but hey, I got everything I needed to put the bike back together even better than it came from the factory and I will be out a total of $1207.00 and this includes turn signal lamps, peg supports, pegs, clutch control, derby cover, mirror, lower stem, 4,5 gallon tank, chrome tank trim panel and probably some other little things I haven't listed. The bike will be better than it ever was from Harley. Hey, does my original gas cap fit the 4.5 gallon tank? At any rate I will keep you updated on the progress and thanks for all the input... You folks are awesome........

[Hoowasat]

Originally Posted by johnkiddier

First, you do not need any additional hardware at all. The bolts from your existing tank swap straight over. The only thing that you might want is the little plastic cover on the forward tank tabs. It seems a lot of money for the sticky back plastic and it's not necessary anyway. Petcock etc just swaps straight over without problems. You'll end up with a 2.5 litre reserve using the petcock from your standard tank.

Ditto on not needing the fastener kit. However, the plastic covers on the front of the 1200R tank are not used with the 1200C tank. I've already done the swap. Also, it's well advised to spend 15-cents for a new petcock seal.

[johnkiddier]

I did the swap last weekend without any problems at all. I couldn't actually get the plastic covers off without breaking them so I never checked if they fit the 'c' tank. They're completely unecessary anyway.

The stock fuel cap will fit either the standard 04+ or the 'c' model tanks. Top tip on the petcock seal, I'll keep an eye out for any leaks. I've done 500 miles since the swap and it's been fine so far.

A nice side effect of the larger tank is that high speed wind buffetting is greatly reduced. Anyone else notice this? As my ride to work is 45 miles each way on highway cruising at 75mph I was taken aback by the difference in the ride.