Installing the Sportster Tank Kit (SR400/500): From Securing the Upper and Lower Plates to Connecting the Fuel Line
Installation steps for the Sportster Tank Kit for the SR400/500 (up to '08). Photos walk you through setting the upper and lower plates on the main frame, securing the tank with the anti-vibration rubbers and collars, and connecting the fuel cock to the carburetor.
- Setting the upper and lower plates on the main frame
- Securing the tank with anti-vibration rubbers and collars
- The fuel line from the fuel cock to the carburetor, and canceling the vacuum hose
The Sportster Tank Kit (G2-00051) lets you fit a Sportster-style tank to the SR400/500 (up to '08).
Following Chapters 01-08 of the instruction manual, this page walks you through installation, then wraps up with a fuel line connection diagram and notes.
01 Setting the plates and securing the tank
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Chapter.01 Lay out the parts included with the tank.
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Chapter.02 Set the base plate under the main frame.
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Chapter.03 Set the narrow plate on top of the main frame.
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Chapter.04 Secure the upper and lower plates with the included screws.
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Chapter.05 Fit the anti-vibration rubbers to the tank.
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Chapter.06 Insert the collars into the anti-vibration rubbers.
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Chapter.07 Set the tank on the frame (the front is the same as stock).
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Chapter.08 Secure the tank with the included bolts and washers.
02 Connecting the fuel line
Run the fuel line from the fuel cock through the hose and filter to the carburetor. Use the included threaded plug on the manifold's vacuum port.
The fuel cock included with this product is not the SR's stock vacuum-operated type. You'll need to cancel the vacuum hose that runs from the intake manifold.
- Use sealing tape when installing the fuel cock.
- Use the included zip ties at each hose joint.
03 Before use
We take every care with the tank itself, but before painting this product, always check for fuel leaks or other problems. If a fuel leak or other problem is found after painting or modification, we cannot cover or compensate for painting or modification costs.
Always check that all fasteners are tight before use. Tighten bolts and nuts to the proper torque. After a tip-over or similar incident, stop using it and be sure to inspect it. If you notice anything unusual during use, stop using it immediately and inspect it. If you are unsure about the installation, be sure to have it done by someone experienced or by a custom shop. For any questions, please reach us through our contact form.
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*Installation is at your own risk. If you're unsure about doing the work yourself, we recommend consulting your local motorcycle shop.
*The content and photos reflect the time of writing. Please check each product page for current specifications, fitment and stock.