Hey guys! Thinking about giving your Honda Shadow 600 a cool, custom look? Swapping out the stock tank for a Sportster tank is a popular mod that can seriously transform your bike's appearance. This guide will walk you through everything you need to know, from why you might want to do it to the nitty-gritty details of the installation. Let's dive in!

Why Go Sportster Tank on Your Shadow 600?

So, why are so many riders opting for a Sportster tank on their Shadow 600? There are a few key reasons. First, the aesthetic upgrade is undeniable. The Sportster tank offers a classic, teardrop shape that many find more appealing than the stock Shadow tank. It gives the bike a more aggressive, custom look that stands out from the crowd. Second, it's a relatively straightforward modification. While it's not a simple bolt-on affair, with some basic mechanical skills and the right tools, it's a project most DIYers can tackle. Third, the Sportster tank is readily available and often more affordable than custom-made tanks. You can find them new or used in a variety of styles and finishes, giving you plenty of options to choose from.

Beyond the visual appeal and cost-effectiveness, swapping to a Sportster tank allows for a bit of personalization. You can choose a tank with a specific capacity, modify the mounting points to achieve a certain look, and even customize the paint job to perfectly match your bike's overall theme. This level of customization is a huge draw for riders who want to create a truly unique machine. Plus, let's be honest, there's a certain satisfaction that comes from wrenching on your own bike and making it your own. This mod is a great way to get your hands dirty and learn more about your motorcycle.

Ultimately, the decision to switch to a Sportster tank is a personal one. But if you're looking for a way to enhance the look of your Shadow 600, add a touch of custom flair, and enjoy a rewarding DIY project, this modification is definitely worth considering.

What You'll Need: Gathering Your Supplies

Before you even think about touching a wrench, you need to gather all the necessary parts and tools. This will save you a ton of time and frustration in the long run. Here's a comprehensive list of what you'll need for your Honda Shadow 600 Sportster tank swap:

• Sportster Tank: Obviously! Make sure you choose one that's in good condition, free from rust and major dents. Consider the capacity you want and the style that best suits your bike.
• Mounting Hardware: You'll likely need to fabricate or purchase custom mounting brackets. The stock Shadow 600 tank mounts differently than a Sportster tank, so you'll need to get creative. Look for steel stock, bolts, nuts, and washers.
• Fuel Line: You might need to replace or modify your fuel line to fit the new tank. Have some fuel-resistant hose on hand, along with hose clamps.
• Fuel Petcock: The Sportster tank might require a different fuel petcock than your stock Shadow tank. Make sure you have one that's compatible with your tank and fuel line.
• Wiring: Depending on the tank you choose, you might need to extend or modify some wiring for the fuel level sensor or other components.
• Tools: A basic set of tools is essential, including wrenches, sockets, screwdrivers, pliers, a drill, a grinder (or a file), and a welder (if you're fabricating your own brackets).
• Safety Gear: Don't forget safety glasses, gloves, and a respirator if you're doing any grinding or welding.

It's also a good idea to have a repair manual for your Shadow 600 handy. This will provide you with valuable information about the bike's fuel system and wiring. Take your time to gather all the necessary supplies before you start the project. This will ensure a smoother and more successful installation.

Step-by-Step Installation: Getting Your Hands Dirty

Alright, let's get down to the fun part: installing that Sportster tank on your Shadow 600! Remember, this is a modification that requires some fabrication and adaptation, so be patient and take your time.

1. Remove the Stock Tank: Start by disconnecting the fuel line from the petcock and draining any remaining fuel. Disconnect the fuel level sensor wiring. Remove the seat and then unbolt the stock tank. Carefully lift it off the bike.
2. Fabricate Mounting Brackets: This is where things get a little tricky. You'll need to fabricate custom mounting brackets to secure the Sportster tank to the Shadow 600 frame. Measure the distance between the mounting points on the tank and the frame. Cut and shape the steel stock to create brackets that will bridge the gap. Use a welder to attach the brackets to the frame or tank (or both). If you're not comfortable welding, you can bolt the brackets to existing mounting points on the frame.
3. Install the Fuel Petcock: Install the fuel petcock on the Sportster tank, making sure it's properly sealed.
4. Connect the Fuel Line: Connect the fuel line from the petcock to the carburetor. You might need to cut and splice the fuel line to get the correct length and angle. Use fuel-resistant hose and hose clamps to ensure a secure connection.
5. Wire It Up: Connect the fuel level sensor wiring to the appropriate wires on the bike. You might need to extend or modify the wiring to reach the sensor. Use butt connectors or solder to make secure connections. Insulate the connections with electrical tape or heat shrink tubing.
6. Mount the Tank: Carefully lower the Sportster tank onto the mounting brackets. Secure it with bolts and washers. Make sure the tank is properly aligned and doesn't rub against any other parts of the bike.
7. Test for Leaks: Fill the tank with a small amount of fuel and check for leaks around the fuel petcock and fuel line connections. If you find any leaks, tighten the connections or replace the seals.
8. Reinstall the Seat: Reinstall the seat and any other parts you removed during the installation.

Important Note: This is a general guide, and the specific steps may vary depending on the Sportster tank you choose and the modifications you make to your Shadow 600. Always consult a repair manual and use caution when working with fuel and electrical components.

Tips and Tricks: Making the Job Easier

Swapping a tank isn't always a walk in the park. Here are some tips and tricks to help you along the way and avoid common pitfalls:

• Measure Twice, Cut Once: This old adage is especially true when fabricating mounting brackets. Accurate measurements are crucial for a proper fit.
• Use Cardboard Templates: Before cutting any metal, create cardboard templates of the mounting brackets. This will allow you to test the fit and make any necessary adjustments before committing to the final design.
• Take Your Time: Don't rush the installation process. Take your time to do things right. This will prevent mistakes and ensure a better result.
• Ask for Help: If you're not comfortable with any part of the installation, don't be afraid to ask for help from a friend or a professional mechanic.
• Document Everything: Take pictures of each step of the installation process. This will be helpful if you need to refer back to it later.
• Check for Clearance: Make sure the tank doesn't interfere with the handlebars, forks, or any other parts of the bike. You might need to adjust the mounting brackets to achieve proper clearance.
• Protect the Paint: Cover the frame and other parts of the bike with blankets or towels to protect the paint from scratches.

By following these tips and tricks, you can make the Sportster tank swap a smoother and more enjoyable experience.

Potential Problems and Solutions: Troubleshooting

Even with careful planning and execution, you might encounter some problems during the Sportster tank swap. Here are some common issues and their solutions:

• Fuel Leaks: If you're experiencing fuel leaks, check the fuel petcock, fuel line connections, and tank seals. Tighten the connections, replace the seals, or use a fuel tank sealant to stop the leaks.
• Wiring Issues: If the fuel level sensor isn't working properly, check the wiring connections. Make sure the wires are properly connected and insulated. Use a multimeter to test the wiring for continuity.
• Mounting Problems: If the tank doesn't fit properly, double-check the measurements and mounting brackets. You might need to adjust the brackets or fabricate new ones.
• Fuel Flow Issues: If the engine isn't getting enough fuel, check the fuel line for kinks or blockages. Make sure the fuel petcock is open and the fuel filter is clean.
• Vibration: If the tank vibrates excessively, add rubber grommets or spacers to the mounting brackets to dampen the vibrations.

By being aware of these potential problems and their solutions, you can troubleshoot any issues that arise during the installation and ensure a successful outcome.

Enjoy Your New Look!

Congratulations! You've successfully swapped out your Honda Shadow 600's stock tank for a Sportster tank. Now it's time to stand back and admire your work. Your bike has a whole new look, and you've gained some valuable wrenching experience in the process. Enjoy the ride!