Finding the right fuel tank for your classic 1991 Harley-Davidson can be a challenge. This guide dives deep into identifying your specific tank, addressing common issues, and exploring restoration options. Whether you're a seasoned mechanic or a novice enthusiast, this resource will equip you with the knowledge to navigate the world of 1991 Harley gas tanks.
Identifying Your 1991 Harley-Davidson Gas Tank
The first step in any repair or restoration project is proper identification. 1991 Harley-Davidson models varied significantly, each sporting different tank styles and capacities. To accurately identify your gas tank, you'll need to consider several key factors:
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Motorcycle Model: Knowing the exact model of your Harley (e.g., FXR, FLHT, XLH) is crucial. Each model year had its unique tank design. Your VIN number, located on the frame, will help confirm this.
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Tank Shape and Size: Take detailed measurements of your tank, noting its length, width, and height. Pay close attention to the shape—is it teardrop-shaped, peanut-shaped, or something else entirely? Photographs can be incredibly helpful in this process.
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Paint and Graphics: The original paint job and any graphics present on the tank can serve as valuable identifiers. Look for manufacturer markings, model-specific emblems, or any unique design elements. These details are crucial for pinpointing the exact tank type.
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Mounting Points and Fittings: Carefully inspect the tank's mounting points and fuel line fittings. The number and placement of these features vary significantly between models.
Common Problems with 1991 Harley-Davidson Gas Tanks
Over time, 1991 Harley gas tanks can suffer from several issues:
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Rust and Corrosion: This is perhaps the most common problem. Rust can compromise the tank's structural integrity and lead to fuel leaks.
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Dents and Dings: Years of use can leave a gas tank with various dents and scratches. These affect both the tank's appearance and its ability to hold fuel effectively.
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Leaks: Fuel leaks can be caused by rust, corrosion, or damage to the tank's seams. This is a significant safety concern and requires immediate attention.
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Paint Degradation: Exposure to the elements and general wear and tear can cause the original paint to fade, chip, or peel.
Repair and Restoration Options for Your 1991 Harley Gas Tank
Several options exist for addressing the issues listed above:
Repairing Minor Dents and Scratches:
Minor dents can sometimes be repaired using a specialized tank dent puller or by carefully applying heat and pressure. Scratches can be addressed with sanding and repainting.
Addressing Rust and Corrosion:
Severe rust often requires professional tank cleaning and sealing. This typically involves removing the internal rust using specialized chemicals and then sealing the tank to prevent future rust formation. This is crucial for maintaining the structural integrity and preventing fuel leaks.
Professional Restoration:
For a complete restoration, consider hiring a professional. Reputable specialists possess the expertise and tools to handle the intricate processes of rust removal, dent repair, and repainting, ensuring a high-quality finish that maintains the originality of your classic Harley.
Sourcing Replacement Tanks:
If the damage is extensive or the repair cost is prohibitive, finding a replacement tank might be necessary. This can involve sourcing a used tank in good condition or purchasing a reproduction tank. Careful research is essential to find a tank that's a precise match for your 1991 Harley model.
Conclusion: Keeping Your 1991 Harley's Fuel Tank in Top Shape
Maintaining your 1991 Harley-Davidson's gas tank is crucial for both safety and aesthetics. Regular inspection, prompt attention to minor issues, and timely restoration efforts will help preserve this vital component of your classic motorcycle. By following the steps outlined above, you can ensure your 1991 Harley's gas tank remains a functional and visually appealing part of your prized possession for years to come.
