The Iconic Custom Profile: V-Twin Mfg. Replica King Tank for 2004-2006 Sportsters

The 2004–2006 Harley-Davidson Sportster models are highly regarded as the peak of the carbureted, rubber-mounted XL era. While these bikes offer a smooth ride and classic soul, many riders find the stock fuel capacity lacking for anything beyond city commuting. The V-Twin Mfg. Replica King Tank is the perfect solution for riders who want to maintain the “Peanut” heritage while gaining the extra fuel volume needed for the open road. This “King” version of the legendary Sportster tank is slightly wider and deeper than the standard 2.2-gallon version, providing a muscular, aggressive look that fills out the Sportster frame beautifully without looking oversized or out of place.

Engineered for the Rubber-Mount Carbureted Era

Precision fitment is essential when dealing with the unique frame changes introduced in the 2004 model year. This V-Twin Mfg. tank is specifically engineered to fit 2004, 2005, and 2006 Sportster models. Because these were the final years of the carbureted Sportster, this tank features the necessary provisions for a standard fuel valve and is not intended for later EFI fuel pumps. It serves as a high-quality alternative or replacement for riders looking to achieve a custom look that honors Harley-Davidson’s traditional design language. Whether you are building a Frisco-style chopper or a clean, daily cruiser, the Replica King Tank provides the structural integrity and historical accuracy your project demands.

Heavy-Duty Steel and Technical Specifications

Durability is a hallmark of V-Twin Manufacturing products. This tank is constructed from heavy-gauge, deep-drawn steel to ensure it can withstand the vibrations of the 883 or 1200 Evolution engine. The one-piece design offers a smooth, seamless surface that highlights the “King” profile’s unique curves.

• Capacity: 3.3 Gallons (approx. 12.5 liters) for improved touring range.
• Petcock Compatibility: Designed for a 22mm external thread petcock (sold separately).
• Gas Cap Style: Accepts 1983-up screw-in style vented gas caps for a modern, secure seal.
• Mounting: Utilizes stock-style mounting points for a secure, bolt-on installation on 04-06 frames.

Custom Preparation and Paint Excellence

This tank arrives in a raw, unfinished steel state, providing a blank canvas for your creative vision. Whether you are planning a classic “AMF” inspired throwback paint job or a modern, high-gloss finish, the smooth surface of this tank is ready for professional bodywork. As with all aftermarket fuel tanks, we strongly recommend that the unit be pressure tested for leaks and internally treated with a high-quality tank sealer before painting. Sealing the interior is a critical step in protecting the steel from the corrosive effects of modern ethanol fuels and ensuring the longevity of your custom paint job. We also suggest a “dry fit” on your Sportster frame before painting to verify clearance against your handlebars, triple trees, and specific seat choice.