installing new 8 gal tank in 503

[feartheride]

What has to be done to install this larger tank. I pulled the cross bar out that supports the smaller tank.Does any one have pics from when they cut out the plastic.How much of it needs to get cut out..Just patch it with thin aluminum from what I've seen.. What else has to be done to support it

What holds the tank in place ,just a rubber strap across the front..The smaller tank had that bracket on the front to help hold it in place

I also need a new tail light lens,do they still sell them or an alternative type,whos using what ?

Anyone have that website that sells wraps, just sheets and you cut to fitI think Tony posted it for me before

[buffaloHAWK]

my 503 already had the big tank but they patched the hole with thin aluminum. the only thing holding it in is the bungee strap across the front...for my taillight i have an led light off my honda crf250x bolted under the fender(i think its broke now or the wire broke)

[Sjr55049]

Originally Posted by feartheride

What has to be done to install this larger tank. I pulled the cross bar out that supports the smaller tank.Does any one have pics from when they cut out the plastic.How much of it needs to get cut out..Just patch it with thin aluminum from what I've seen.. What else has to be done to support it

What holds the tank in place ,just a rubber strap across the front..The smaller tank had that bracket on the front to help hold it in place

I also need a new tail light lens,do they still sell them or an alternative type,whos using what ?

Anyone have that website that sells wraps, just sheets and you cut to fitI think Tony posted it for me before

http://www.powersportswraps.com/

[Thunderhawk]

Here's some pictures of when I did mine. After cutting the opening, I used a layer of sheet rubber kind of like a huge gasket, then the thin layer aluminum, both from the local hardware store. As you can see in the last picture, I also generously chaulked it.








The ends of the old cross bar you cut out need to be reused for holding the tank in place. I'll try to get a picture of that tomorrow.

[feartheride]

Thunderhawk

Thanks pics speak volume..
Looking forward to pic of brackets ,I will save cross bar and machine some new pieces when you post pic

[Sjr55049]

don't forget rub pads
I glued on a piece of rubber flooring on the front mount plate.
I cut a piece of fuel line and hold it in place by industial heat shrink, I also use the same heat shrink tubing on the handlebars to insulate the warmers.

[TLKD]

Wow, was that ever a big steering column plate on the 503s !

[feartheride]

Originally Posted by Sjr55049

don't forget rub pads
I glued on a piece of rubber flooring on the front mount plate.
I cut a piece of fuel line and hold it in place by industial heat shrink, I also use the same heat shrink tubing on the handlebars to insulate the warmers.

your one pic is of a 600 correct

Trying to think what I can use for rubber up there..I have some nice black hydro turf which is what we use for traction on standup freestyle jet skis but it is 1/4" thick

[Travis616]

The taillight for the '03+ hawks is off of a polaris four wheeler. A 2000 sportsman 500 or something like that is the same. Most dealers can get it aftermarket for less $$$.