A
Things you will need extra:
- (8) 1/4" bolts 1/2" long with flat washers (2 for tank mount, 4 for seat mount and 2 for Light mount)
- Extend your tail light wiring harness AT LEAST 7"
-30" of 3/8" fuel line to extend pickup out of 3.5 gal tank. (or use stock 8.8 gal pickup--recommended by Trail Tank)
Tools you will need:
-T25 and T27
-Metric socket set
-Small pry bar or screw driver (to install front hold down spring)
-pliers or channelLock for fuel line
-Large Sledge and duct tape (on stand by only)
Start by Turning Fuel "off", removing the side panels, belt guard, belt, driven clutch and airbox.
Move to the back of the sled and removed the four seat hold down bolts under the tunnel. (2 easy in back and 1 on either side of the tunnel up above rear scissor). Some people like to pull the rear skid to make it easier, but it isn't necessary.
On 08 and newer sleds Remove the T27 screws on either side of the seat hold down and removed the seat. On 05-07 sleds, slide seat rearward and remove.
Unplug the tether, hand warmer controls and unbolt the choke lever. Remove the 4 T25 screws THEN the gas cap and pull off console piece.
On the carburetor side of the fuel shut off, disconnect fuel line. Then pull the front hold down spring forward lift old tank out.
If you have the rear mount for the racer tank left on the sled, get a drill and a 3/16 drill bit and drill out the 5 rivets that hold it down and remove it.
Now you should have a bare tunnel.....I hope
Remove the black plastic from the rear of your tank (6 T25 screws) and then remove the tailight from that. You should now have a bare seat.
Remove the Fuel pickup from your old tank and save.
Install: WARNING DO NOT USE THE POINTED TORX FASTERS OR ANY FASTENERS OVER 3/4" or you WILL DAMAGE YOUR TANK!!!!
Make sure to extend your tail light wiring 7 inches or more. Install tail light onto supplied tail light bracket with the nuts in the recesses on the bracket. Install tail light on tank using two of your 1/4 bolts that are 1/2" long and washers.
Remove the old 3/8" fuel line off your old fuel pick up and install the 30" piece of new line so your fuel stainer will be at the back of the new Trail Tank. Install Fuel pickup in Trail tank by inserting large orange grommet in tank and feeding the pickup through it until the brass elbow plugs in.
Now install the tank on the sled. PLUG IN THE TAIL LIGHT!!!! Start by feeding the fuel pick up under the front hold down spring. Use a small pry bar or screw driver to pry spring over hold down lip. Next move to the back of the sled and install (2) 1/4" bolts with washers.
Slid the console over the tank, install gas cap (so you don't drop bolts down it) and install the 4 Torx screws that hold the console down. Plug in tether, hand warmers and choke lever. Route fuel line and plug in.
Flip the bare seat over and install the front and rear seat mounts to the seat pan using the T25 screws that held the original plastic on. The front and rear mounts are shaped like an "L". On the rear mounts, the "L" goes to the outside on the front mounts the "L" faces the inside. (see pics)
Using (4) of the 1/4" bolts that are 1/2" long LOOSELY install the seat on the Trail tank. Install front T27 Hold down screws and tighten front and rear seat mount bolts.
Install airbox, clutch, belt, guard and panels and go Tear it up!
- (8) 1/4" bolts 1/2" long with flat washers (2 for tank mount, 4 for seat mount and 2 for Light mount)
- Extend your tail light wiring harness AT LEAST 7"
-30" of 3/8" fuel line to extend pickup out of 3.5 gal tank. (or use stock 8.8 gal pickup--recommended by Trail Tank)
Tools you will need:
-T25 and T27
-Metric socket set
-Small pry bar or screw driver (to install front hold down spring)
-pliers or channelLock for fuel line
-Large Sledge and duct tape (on stand by only)
Start by Turning Fuel "off", removing the side panels, belt guard, belt, driven clutch and airbox.
Move to the back of the sled and removed the four seat hold down bolts under the tunnel. (2 easy in back and 1 on either side of the tunnel up above rear scissor). Some people like to pull the rear skid to make it easier, but it isn't necessary.
On 08 and newer sleds Remove the T27 screws on either side of the seat hold down and removed the seat. On 05-07 sleds, slide seat rearward and remove.
Unplug the tether, hand warmer controls and unbolt the choke lever. Remove the 4 T25 screws THEN the gas cap and pull off console piece.
On the carburetor side of the fuel shut off, disconnect fuel line. Then pull the front hold down spring forward lift old tank out.
If you have the rear mount for the racer tank left on the sled, get a drill and a 3/16 drill bit and drill out the 5 rivets that hold it down and remove it.
Now you should have a bare tunnel.....I hope
Remove the black plastic from the rear of your tank (6 T25 screws) and then remove the tailight from that. You should now have a bare seat.
Remove the Fuel pickup from your old tank and save.
Install: WARNING DO NOT USE THE POINTED TORX FASTERS OR ANY FASTENERS OVER 3/4" or you WILL DAMAGE YOUR TANK!!!!
Make sure to extend your tail light wiring 7 inches or more. Install tail light onto supplied tail light bracket with the nuts in the recesses on the bracket. Install tail light on tank using two of your 1/4 bolts that are 1/2" long and washers.
Remove the old 3/8" fuel line off your old fuel pick up and install the 30" piece of new line so your fuel stainer will be at the back of the new Trail Tank. Install Fuel pickup in Trail tank by inserting large orange grommet in tank and feeding the pickup through it until the brass elbow plugs in.
Now install the tank on the sled. PLUG IN THE TAIL LIGHT!!!! Start by feeding the fuel pick up under the front hold down spring. Use a small pry bar or screw driver to pry spring over hold down lip. Next move to the back of the sled and install (2) 1/4" bolts with washers.
Slid the console over the tank, install gas cap (so you don't drop bolts down it) and install the 4 Torx screws that hold the console down. Plug in tether, hand warmers and choke lever. Route fuel line and plug in.
Flip the bare seat over and install the front and rear seat mounts to the seat pan using the T25 screws that held the original plastic on. The front and rear mounts are shaped like an "L". On the rear mounts, the "L" goes to the outside on the front mounts the "L" faces the inside. (see pics)
Using (4) of the 1/4" bolts that are 1/2" long LOOSELY install the seat on the Trail tank. Install front T27 Hold down screws and tighten front and rear seat mount bolts.
Install airbox, clutch, belt, guard and panels and go Tear it up!
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