This video covers the installation of a Blackbird Legacy Gas Tank on a 2006 Harley-Davidson Sportster. Blackbird Legacy Gas Tanks are available for the carbureted, 1986-2003 year range as well as the 2004-2006 carbureted bikes with the later style gas tank mounts, and also the 2007 and later EFI fuel injected Sportsters. The install is pretty much the same, with some slight differences based on year. These gas tanks install easily using stock hardware into the stock locations, and completely change the look of your bike so it stands out from the rest! There are standard width as well as narrow Slimline Blackbird gas tanks for 1986 - current H-D Sportsters available at Lowbrow Customs. If you do not have enough time to watch a full video, read a complete guide post about installing the BlackBird gas tank here with very detailed instructions and images.
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You can read a full transcription of this video below:
Hey guys and girls, Todd from Lowbrow Customs here. Today we're going to show you how we're going to change out the gas tank, we've got this new Cycle Stardard Blackbird Legacy gas tank, it's going to slim down your bike, it's going to look awesome. Obviously the ones we have here today are not painted but you can send it off to your favorite painter and get that crazy psychedelic 70’s paint job and get your freedom machine looking cool.
All right, let's go ahead and get started. Okay, let's take a look at the gas tanks real quick here. This is the original Blackbird gas tank. This one holds three and a half gallons approximately. You'll notice the mounting system on here, this is designed for the bike we're working on today, which is an 04 to 06 year range Harley-Davidson Sportster. We also have this tank available for 86 to 03 year range and we also have this tank available for 07 and up when Harley-Davidson went to the fuel injection on this fine motorcycle right here.
For the other tank we're going to show you today, this is a new tank that we just came out with, this is the cycle standard blackbird slim line. These are not available for the fuel injected models because there's just not enough room on the bottom of the tank to put the fuel pump assembly, but it is available for the other year ranges. Another cool thing we did for you guys out there that don't want to put this on your Sports to say, you want to put it on some other model or make, we have a universal tank that comes without the mounting bracket on it. It does come with some brackets in the box if you want to use those or if not you can make your own brackets, but if you do want to put this tank on a Kawasaki or a Honda or whatever else you might be riding out there.
This tank holds approximately 2.5 gallons, about a gallon less than the other one but you got to pay the price to look cool. Just takes a few simple hand tools to remove the gas tank.
If you've watched my other videos, I always like to have my nice long extension and that keeps me well away from the gas tank. We'll go ahead and remove the front and rear bolts on here, right in there like that.
That's a pretty long winded vault we got on this motorcycle and nut. Wall off, go on and remove. On this model it wasn't necessary to remove the seat, now we got the two front rear mounting bolts removed, we got to disconnect the fuel valve which is on this side of the motorcycle, we also have these holes over here, we'll show you real quick. If you look underneath the tank, you're going to see a 90 degree rubber fitting, this is your anti vapor valve, pops right off like so, badabing badabang.
On most Harley fuel line clamps they are a pinch together type of clamp. This one has a standard hose clamp because its tank’s been off here before and replaced with a different one. On that stock clamp what you want to do is take a parasite cutters and bend it and carefully cut through it, a pair of pliers, pull it open, pull it off. Be careful when you’re doing that, they are sharp after you've cut it.
We’ll go ahead and take the fuel line off and if you have a fuel valve that is not a vacuum style fuel valve, make sure you turn it off before you disconnect the hose. In addition to removing the fuel line off the valve if it is a vacuum style fuel valve which is found on the majority of the modern Harleys, there's going to be a vacuum line on the back side of it, you want to get to the back side of there and pop that off before you try to take the tank off the bike or that will be holding you back. Just to reviewed before we remove the tank we've got rear mounting bolt, front mounting bolt, anti vapor valve, rubber line, fuel valve and a vacuum line on the petcock.
Now on some models you've got to be real careful the front as you're lifting the tank off that it doesn't bang into things. Okay, if you are going to use a non vacuum type fuel valve, this is the vacuum line that we removed from the stock valve. If you may notice if you look on the other side here, the other end of that line is attached to the back side of the carburetor and basically that's manifold vacuum. Whenever the engine's cranking, that applies vacuum to the stock Harley fuel valve, opens a rubber diaphragm and lets the fuel flow.
If you are going to use a non vacuum type fuel valve, you will need to remove this from this point right here and put a rubber cap over that otherwise you'll have a very large vacuum link and if you're just going to reuse your stock Harley value to just re-hook up everything the way you found it when you took it apart.
All right, the new tank does come with a hardware package, if you want to reuse your old stuff that'll work just fine, if you want to use a new stuff you can do. This tank will accept a 22 millimeter fuel valve of which we have multiple choices on the website. I chose the straight down one because that resembled the valve that was on the original tank, was facing straight down, it will reconnect to the fuel line very easily.
Okay, fuel filter look on there it's got a couple of little knobs and if you look on the valve body it has two that those correspond to. I'm just going to push that on there, you also may notice that we have this thread of cup or not, it has threads on this side and internal threads here, this will work, the purpose of that is when you thread this on the gas tank you want to be able to orientate the valve facing out. If it didn't have the ability to have threads on top and bottom may end up with it facing that way it's pretty difficult to turn on and off if it's facing in versus out.
Okay, I went head and removed the seat when you guys weren't looking, probably not a bad idea just to remove it at the beginning of the job that will make it much easier to put the tank on. One of the things worth mentioning is anytime you are installing a new part on your bike especially if it's a painted part, it is a good idea to trial fit it before you send it to your painter to make sure everything's working correctly, it's fitting nicely, you may find that you need to bend these this front tab out just to gaude to clearance the coil bracket here which is sandwiched in between the tank and the frame mounting point.
It has fallen off of the little knob on there, basically if you look on the frame you can see it's got a little square that the coil bracket locates in, if it's not located correctly the tank doesn't want to go on. Basically as you're sliding that on, you want to pay attention that both sides of the inside of the tabs are cleansing that coil bracket or will fall off.
We can go ahead and put our bolts back in. There's how it’s going to look like when it's installed. Then all you have left to do is you're going to re-plug in this fitting here to the fitting on the bottom here, once again that's your entire vapor valve. You’re going to go ahead plug gasoline back on We got our front and rear mounting bolts on. Obviously, you're going to get your washer and you lock down on there. Now, you're going to fill up your tank. We do have some really nifty gas caps. Available on our web store. Fill up your tank, put your new cap on if you so desire to get one of these really slick Lowbrow customs fuel caps. Works just like the stock one. That one says fuel, this one is pretty cool. Put your seat back on and thanks for watching. Go for a ride.