(1.) The OE carbureted tank (Right) has the fuel level indicator in the left side of the tank whereas the EFI tank has a large hole in the center in which the fuel pump and fuel level sender are located.
(2.) The underside of each tank shows the carbureted tank with a single outlet for the petcock, while the old style EFI tank has two smaller ports.
(3.) To fix the issues of the rust in the tank as well as the EFI to carburetion conversion, parts from Harley-Davidson, Pingel and MC Advantages were used.
(4.) Inside the tank there were bits of the OE tank liner peeling as well as a few spots of rust that needed to be eradicated.
(5.) To the rescue was the Stampede three-part tank liner kit, which is designed for unpainted tanks, but with care we tried it on a painted tank.
(6.) We started the inner-tank cleaning process by inserting pieces of chain into each side of the tank and rattling the tank around for 30 minutes. This did a great job of breaking up any loose and lingering bits of old liner and rust.
(7.) Once the tank was flushed with water and dried, we added the Stampede Fuel Tank Cleaner and swished it around for 20 minutes before washing it out again.
(8.) We dried the tank out with a hair dryer, plugged the outlets, then cautiously poured in the Stampede fuel tank prep liquid. The prep contains a harsh chemical known as MEK, which can damage the outer painted surface when swished around the tank.
(9.) With the preparation steps complete, we moved onto the tank lining. Wanting to be able to better control the flow of the liner, we punched a small hole into the top of the container.
(10.) The consistency of the liner comes out similar to honey, so we took our time and made sure to coat the inside of the tank by moving it around in all directions.
(11.) As you can see in the photo, the liner seals the tank with a healthy coat while the top has yet to be completed. Once the rest of the tank was completely covered, we let the liner dry overnight.
(12.) Now that the liner was in the tank and ready to go we moved onto the EFI to carburetion conversion. Luckily for us, Pingel had a kit to convert both the '95-01 Magneti-Marelli and the '02-09 Delphi EFI units to any 22mm petcock.
(13.) We simply removed the EFI plugs, chased the threads and inserted the Pingel conversion. It was now ready to have the Pingel 22mm Powerflow petcock installed.
(14.) The Powerflow Petcock is a very well made part with smooth-as-butter operation and a top-notch chrome finish.
(15.) To fill the rather large void in the top of the tank, we used a '95-07 OE Harley-Davidson tank canopy and hardware.
(16.) The tank canopy hardware had special seals on them so no gasket was required once the canopy was tightened down to factory specs.
(17.) Even the OE vent tube and dash attachment hardware were in the same location on the EFI canopy, making this conversion an easy one to accomplish in a few short hours providing that the tank is not rusty.
(18.) The tank was now cleaned, converted and residing in its new home atop the Lonely King all within 48 hours.
EFI To Carb Fuel Tank Conversion
When it was time for a paint upgrade on our project Lonely King, we hit up the swap meet for a nice fuel tank to send out with the upgraded sheetmetal. The tank we found was straight and looked like it just came off a bike, so off it went to paint.
The only problem was when it came back from getting layers of flake, candy and pinstriping on it, the tank we bought suffered from a case of mistaken identity. The bike is a carbureted '97 Road King and the tank that we scored at the swapmeet was for an EFI model. What's the difference you ask? The bottom of the EFI tank has no provision for a petcock and it has a huge hole in the top of the tank meant for the fuel pump and the fuel gauge sending unit.
Thankfully, the top of the tank was not that big of an issue since we just ordered a new tank canopy and bolts from Harley-Davidson, which fit just like they were supposed to.
The bottom of the tank was a different issue all together. We were a bit upset at the thought of having to drill a huge hole in the bottom of the tank and ruin the killer paint job that Airea 5150 did for us, so we went in search of something that could convert the tank. While asking around and probing the Internet for a solution, we went to Pingel's website and to our surprise, found a conversion kit readily available.
With the parts from H-D and Pingel in hand we thought our troubles were over until we started looking closer at the inside of the tank. While peeking around inside we noticed a few microscopic hairline cracks and some peeling in the OE tank liner and bits of rust hidden under them. Knowing that this should be taken care of well before the tank would be used, we had to find an easy to use kit that would be kinder to the paint than other kits. We found a Stampede tank lining kit from MC Advantages and decided to give that a shot while we still had the tank on the bench.
(PN 75228-04A, $120)
Tank Canopy Bolts
(PN 1311D, $6.50)
Stampede Liner Kit
(PN STN01258, $59.99)
EFI to Carb Conversion Kit
(PN 62052, $41.70)
Fuel Valve Petcock
(PN 1311-CR, $94.99)