The new 2020D version is the result of some damage to the mold in the ring area. So while we were remaking the ring I made a few changes. The biggest change is that you no longer have to countersink the fender support brackets and install countersunk bolts. Also, it's not necessary to modify the lockring itself. This should save 30min-1hr of install time. The countersunk bolts was frequently missed and caused people grief. This also makes install on the '06SE easier as there should be no mods necessary to the fender support brackets on this odd-ball model. Sorry for the price increase, but the mold repair was quite expensive and we have to pay for it somehow.
The V-Rod is a great motorcycle capable of so many different styles of
riding. However, the small tank on the V-Rod has always been a bone of
contention among owners.
I have run out of fuel several times and know all too
well that pushing a 600+ lb V-Rod is no fun task. I've yet to put more than 3.4
gallons back in which seems to be the real pumpable capacity of the stock tank.
A couple of these times were in dangerous places where I felt very much at risk,
like the Interstate on the South Side of Atlanta at 1am. I pushed the beast 5
miles that night, I sure wasn't leaving it. Another time on alligator alley in
Florida, talk about being in the middle of nowhere. When traveling in areas
where I didn't know the next gas station, I might stop at every one I see (once
you've pushed the V-Rod for miles late at night your perspective and fear point
on low fuel change radically.)
Returning from my 2004 November & December 2500 mile adventure (where I'd run
out of gas a couple times) I was determined to make a new tank for the V-rod.
And today we have a 5.3 Gallon (20 liter) tank that everyone can install.
- Made in America by Americans for your American motorcycle.
- 5.3 US Gallons (20 Liters) after normalization*. This will yield
approximately 5 1/4 gallons of useable fuel capacity which is a 54% increase
over stock useable of 3.4 gallons - almost 2 gallons.
Included in the kit:
- State of the art molding process gives unparalleled safety. The crash
testing lab performed tests to American and European safety standards. The tank
passed easily. They were instructed to increase the forces until the tank
failed. They were unable to achieve a failure even when hitting the tank with
many times the force set forth in the standards - they maxed out their equipment
- Relocates the ignition out from under your butt to an easy to reach and much
more natural position for the key.
- Included parts to stop the key fob from flapping in the wind.
- Retains normal operation of the ignition and seat latch.
- Designed to fit 2002-2006 VRSCA, B, D, SE and SE2 models.
- Tank Strap
- NASCAR developed thermal barrier
- Ignition Relocation kit
- Ignition bracket
- Ignition wire harness extension
- Extended seat release cable
- misc hardware
- Skid Plate kit
- Formed skid plate
- Aluminum Rivets (stainless steel rivets available on request at no extra
charge - the SS ones are much stronger and take a beefy tool to install.)
- 3/16" drill bit
- Misc hardware
- Detailed installation instructions, which are also
Emissions, EPA, CARB, TUV:
- Install is pretty straight forward. Someone who's done a few can accomplish
the job in 2-3 hours. A first time do-it-yourselfer can easily accomplish the
task in a weekend. We've had numerous male and female users with little or no
mechanical experience complete the installation without difficulty.
- There are detailed instructions.
- It's received the blessing of the EPA and is legal everywhere in the USA
- CARB & TUV approvals are next on the task list, for now it'll be listed as
"not for use in California on pollution controlled vehicles".
- We have 24/7/365 support in our
support forum where you will not only have access to the company owner, the
designer, shipping & receiving, but also others who have done this install on
their own bikes. These are people with a wide range of abilities and even other
languages. You will also find a
gallery of installs where you can see first hand what others have done.
Modifications to stock equipment:
- The stock frame may (or may not) have sharp items sticking out into the tank
area. These could be drippy weld excess, leftover mig wire and splatter. The
tank will fit without modification and it's very doubtful that even the worst of
these could actually puncture the tank, but good sense says that you don't want
to leave these sharp items in potential contact with your new tank that's
holding a flammable liquid. A file or dremel and a little touchup paint and a
few minutes of your time is all that's needed to create a smooth bed for your
new tank to lay in.
- Bend the stock skid flat and install the skid extension. NO cutting is
- Use a heat gun to slightly reform the stock mudflap.
- Saddle bag supports need the frontmost hole countersunk and replace the hex
head bolt with a flat head. (if still in use and many people remove these). '06
SE2 needs a little more modification to the saddlebag support,
contact us for
Shipping & delivery:
Known compatible items. The following is brief list of items that
have tested and are known to work. This will grow over time and we'll be
updating it as we get reports on items that work.
- The box going to be pretty large, I'm currently estimating freight at $55
for FedEx Express 3 day service in
the US48 and $20 for ground which we'll use as a flat rate for now. If you are outside the US48
please contact us on shipping costs. The website will not automatically
calculate shipping outside the US.
- International customers can NOT use a credit card. I'm sorry about this, but
it's the way it is with international credit card rules & regs being what they
are. Western Union, Bank Drafts, Money Orders and Wire Transfer.
- Absolutely NO PayPal. For a few thousand reasons why go to
Known incompatibilities. Getting 5.25 gallons in the same space as the
stock 3.4 tank is no easy trick. Obviously some aftermarket items that deviate
from stock will not be
compatible. We'll list these as we learn of them. If you can't get it to fit
your bike for some reason you may return it for a refund in exchange for
documenting the incompatibility (words & pictures) so that we can add it to the
- All the HD seats
- Corbin Dual Tour
- Modified stock (pushed left for wide tire fitment)
- CFR swingarm
- Kit has been tested with everything from stock up to 250 and we
don't anticipate any problems with tires larger than 250.
- All shocks should fit. The limiting factor is the collapsed length
which should be the same on all V-Rod shocks = 10.4", however even if it
collapses more, the tire will hit the frame before it hits the tank.
- HD's chrome side cover 66310-02 or 66316-04DH or 66357-04 (need to
trim tabs down a little) and chrome button 51636-06
- HD's frame bag kit 94204-03A.
- Right rear passenger footpeg mount on VRSCD models. We have two
- If you are running an aftermarket pipe you can switch to the A, B, SE
model footpeg mounts. This will move your passenger's feet down and forward
for which your passenger will thank you greatly since it's a much more
comfortable location for her feet.
- A newly designed mount and exhaust hanger for stock bikes is in the
- HD's passenger floorboards. The mounts are weird and are very different
from the A, B, SE mounts which the tank was designed for. I studied this for
a customer and it appears that a small notch could be cut in the right side
mount to clear the tank.
- Kuryakyn™ Passenger Peg Mounts.
- Turbos & Superchargers that use the space where we put the ignition.
There are alternatives like HD's up front key location and the keyless mod
(use the alarm to activate the bike.)
Warranty. 1 year on parts for manufacturing defects to the original
This is the
tig welded stainless steel tool we designed and manufactured to remove the big threaded ring on the top of the
tank that holds the sending unit in. You need something like this to remove the
threaded ring and also to reinstall it and torque to recommended specification
of 40-45 ft-lbs. You may be able to get the HD one locally, borrow it, or use an
alternate tool to do this, but you need to ensure that you can properly torque
RevB of the tank kit, we have updated the kit in several ways to make
- The item which is probably of biggest interest is the reduction of height.
The original (RevA) kit is 12mm (less than 1/2") taller than stock. We've
reduced this by 6mm. The benefits of this are
- No need to modify the sending unit
- greater clearance between the top of the tank and underside seatpan
- more clearance at the cap,
- more clearance at the fuel lines, with RevB there is approximately 3/16" of
clearance between the top of the fuel line connectors and the top of the frame.
• 2" more length on the ignition extension wires (which plug in, you
don't cut anything),
• change to aluminum rivets (to make install with cheep rivet guns easier.)
The stainless rivets are available on request.
• modified the tooling on the skidplate to wrap it more fully around the
• Ignition bracket has been modified to cover the wires more making it more
While the original was very easy to install, these little changes should
make installation even easier.
Feel free to ask questions, we'll
expand on this page as need be.
Q: When will it be available?
A: It's available now. We are in steady production.
While there may be
fluctuations in availability due to demand, we should be
able to fill orders quickly.
Q: Will it fit the VSRCR?
Q: What about governmental regulations?
A: The system is designed to meet all governmental
regulations. It's received the US EPA's blessing. CARB and TUV are next.
Q: Where is it made?
A: Start to finish entirely Made in America
Q: Will the fuel gauge be more erratic with this?
A: No, the erraticness of the sending unit won't
get worse. If anything, it'll improve since you'll have the opportunity while
installing this to clean the sensor strip. There is greater volume at the bottom
of the tank than stock so you'll have quite a bit more range when your fuel
gauge reads 1/4 and below than you did with the stock tank.
Q: I see you are changing the skid plate and
extending it, will I have to weld it in place?
A: No. We will offer two different skids. The
default one will be a rivet in skid plate. We will also offer a weld in
replacement for people doing frame out work.
Q: Will I have to make extensive frame
A: No. I'm seeing a lot of griping about this part
of the install and IMHO it's getting blown out of proportion. Based on what
we've seen in the installation trials the new tank will fit right in without any
further modifications. However, it is possible that the space you are putting it
into has some very rough sharp points (mig wire, splatter and drippy welds.) Add
in some vibration (you can see where the stock tank has chaffed the paint off)
and common sense says that you don’t want these sharp pokey things ever touching
or rubbing your new tank that’s holding a flammable liquid. Later ('04+) frame
years were greatly improved in this area, but the early models ('02-'03) can be
a little, shall we say: ‘rough’. I like to think of this of this part of the
installation like making a nice smooth bed for the new tank to lie in. Is it
required? NO. The tank will fit w/o. I highly doubt that even the worst of these
could ever pierce the tank, but still, I think it only makes sense to smooth out
any rough spots. However, as the installer you can certainly choose to ignore
our recommendations. Should you choose to do it as recommended the process is
very easy and while it's true you'll break the painted surface, the places you
do so will be completely hidden by the new tank and a little touchup paint will
prevent any rust. If it were me I'd smooth it out no matter what tank I put in
Q: What about safety? Harley couldn't do it
without changing the bike.
A: You are confusing decisions made by the bean
counters to keep costs down with what the system is capable of. The process we
are using is much more expensive than the OEM part, making it unsuitable for
Harley because of cost, not safety.
Q: What about the California Carbon Canister?
Those of us in CA have to keep this to stay legal.
A: We use the space where this is currently for
fuel, the Carbon Canister will have to be relocated. We will offer a bracket to
Q: Will it work with the alarm & siren?
A: Yes. The alarm stays in the stock location and the siren is relocated but the wires are plenty long enough and
there’s space for it.
Q: Will it work with Phat tires, that is: 240s, 250s, 300s and beyond?
A: Yes, my bike has a 250 and it works fine. Should fit any size tire.
Q: Will it work with models that have a seat release button (ignition isn’t in
the tank area.)
A: Yes, It’s the same as an ignition, just without the switch. So
it will work by relocating the button with the ignition relocation kit.
Q: What about dealers? Will they have access to this kit? What about
A: Yes, we are developing a dealer network.
Q: Can ’07 tanks fit the pre-’07 frames? Can this tank
fit the ‘07s and later?
A: No, HD made changes to the frame and they are not compatible in either
direction, this tanks for '02-'06 only (should fit all excluding the VSRCR.)
Q: Will installation of this tank affect my
A: No, I can’t imagine any way that it could - see the Magnuson-Moss act.
*Normalization: The tank will expand with exposure to gasoline. That's one of
the properties of the material. We have to plan for this in the design or it'd
never come out again so we design it a little smaller than what the final size
is expected to be.
The latest measurement was done by weight which is about as accurate as we can
get. A brand new RevA tank measured out at 5.04 gal and the one that was in my bike
from September to early December (in there about 80 days) measured at 5.35 gal.
The 5 & 4.9 numbers were the day after it was first exposed in September.
We lose about 1/10th of a gallon to the pump & sending unit and airspace at the
That's how we get 5.25 gallons of usable fuel after normalization.
According to studies that have been done it should do 90% of it's growth in the
first 90 days and stabilize around 120 days.
The one with 80 days of exposure measures almost exactly what the computer
predicted it would be.
Bear in mind it is plastic and plastic changes with temperature so you can
expect it to hold slightly more in the heat of summer and slightly less in the
cold of winter.
The above measurements were taken at room temperature, 70°F.
A brand new RevB tank measures 5.13 gal with initial useable capacity of 5.04
gal. We expect the same growth with the RevBs which should yield somewhere in
the 5 1/4 useable gallons. We'll update this after 3-4 months.