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Old Sep 29th, 2011, 10:29 AM     #1
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Sportster Questions

Ive made Heat Deflectors for a 1200cc 2007 Sportster.
This one is fuel injected. Im trying to verify if the pattern Ive made will fit from 2004 to present.

Are all sportsters from 2004 to present fuel injected?

Are the fuel tanks on 2004 to present the same size?

On some of the 2004 photos I looked at. The owners had chrome side covers. Are these chrome covers replacements for the OEM covers? Or are they just chrome covers to be placed over the existing OEM covers?

Thanks in advance, RJ
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Old Sep 29th, 2011, 10:58 AM     #2
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Re: Sportster Questions

Quote: Originally Posted by zoood View Post
Ive made Heat Deflectors for a 1200cc 2007 Sportster.
This one is fuel injected. Im trying to verify if the pattern Ive made will fit from 2004 to present.

Are all sportsters from 2004 to present fuel injected?

Are the fuel tanks on 2004 to present the same size?

On some of the 2004 photos I looked at. The owners had chrome side covers. Are these chrome covers replacements for the OEM covers? Or are they just chrome covers to be placed over the existing OEM covers?

Thanks in advance, RJ
No

No

Replacements
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Old Sep 29th, 2011, 04:21 PM     #3
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Re: Sportster Questions

Is it just the 48 that has the shorter gas tank?

RJ
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Old Sep 30th, 2011, 02:33 PM     #4
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Honestly I'm not sure. I've got an '05 1200c and I have the longer/lower 3(something) gallon tank. But it is carbed.

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Old Sep 30th, 2011, 03:13 PM     #5
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Re: Sportster Questions

Quote: Originally Posted by jeepin View Post
Honestly I'm not sure. I've got an '05 1200c and I have the longer/lower 3(something) gallon tank. But it is carbed.

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Where is the fuel petcock located at? In relation to the end of the tank by the seat? Is it in the center of the tank?, just as it is with the fuel injected type?

So far what I made for the sportster seems to fit the ones with the 4.5 gallon and the next size down, guessing,... I'd say a 3.5 gallon tank. I think there's 3 sportster size gas tanks. Can anyone tell me the capacities?

RJ
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Old Sep 30th, 2011, 11:14 PM     #6
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Re: Sportster Questions

Quote: Originally Posted by The Tank View Post
RJ,
Take a look at this page that I am linking...

Harley-Davidson Sportster Motorcycles: Reviews, Prices, Photos and Videos

Near the bottom of the page you can search on every model and it should get you answers on gas tank sizes for the various Sportster models over the different years of production.

For example here is a search I did on the 2005 Custom 1200. The results said it had a 4.5 gallon gas tank.

2005 Harley-Davidson Sportster 1200 Custom Reviews, Prices, and Specs

You gotta be careful with those specs when designing a part though. The fuel capacity STATES 4.5 but the tank is 3.5 and the lines hold 1 gal. So when my gas light comes on and I switch the selector to RES I use the remaining 1 gal in the lines.
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Old Oct 1st, 2011, 12:49 AM     #7
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Re: Sportster Questions

Quote: Originally Posted by The Tank View Post
That is one long fuel line if it holds 1 gallon of gas.
I'm just saying. My fuel capacity my be 4.5 but I ran the tank dry not switching to RES and fit 3.48 gal in
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Old Oct 1st, 2011, 02:46 AM     #8
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Re: Sportster Questions

Hello Zoood, good hearing from you. Answers to your questions are in blue

Quote: Originally Posted by zoood View Post
Ive made Heat Deflectors for a 1200cc 2007 Sportster.
This one is fuel injected. Im trying to verify if the pattern Ive made will fit from 2004 to present. The standard 1200cc Custom (chrome trim, single caliper up front) and the Roadster share the same side cover pattern. Sportsters had a common problem with the covers "falling" out of the retaining clips. I used chrome screws to fasten the side covers to the plastic retaining clips, others used ip ties. How are you fastening the heat deflectors? I would be interested in buying a set and checking fit on my 2004 XL1200 Roadster, black w/chrome studs.

Are all sportsters from 2004 to present fuel injected? 2007 to present are fuel injected and have fuel pump in the tank. 2004-2006 are carbed, but have two tank profiles, 2.5 gal "Peanut" tank 883R & 1200R(Roadsters), and 4.5 gal tank on 883C & 1200C (Customs). The tank profiles with the 2.5 gal tank and 4.5 gal tank. New 2010 Superlow has 4.2 gal tank (unique)

Are the fuel tanks on 2004 to present the same size? 2004 to 2006 were carbureted, so the fuel tanks have vacuum diaphram fuel petcock only. The 2.5 gal "Peanut" (actually squared corner) short shape is on the 883R & 1200R up to 2009 when model was disconinued. Now very few models use peanut tank these days (you will see frame tube between tank and seat (primarily for nostalgia on some 1200cc models), but all 883C & 1200C models use 4.2 gal tank. Running out of gas to me is not nostalgia I care for...go figure.

On some of the 2004 photos I looked at. The owners had chrome side covers. Are these chrome covers replacements for the OEM covers? Or are they just chrome covers to be placed over the existing OEM covers? The chrome covers are an H-D accessories option, replacing the OEM covers.

Thanks in advance, RJ
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Old Oct 2nd, 2011, 01:44 PM     #9
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Re: Sportster Questions

Quote: Originally Posted by NEWHD74FAN View Post
Hello Zoood, good hearing from you. Answers to your questions are in blue
Thank you. Ill have to review and digest all that you've written. You had asked - How are you fastening the heat deflectors?

I made them extremely easy to install as shown in the following pictures.





RJ/Zoood
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