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Pan America "Tin Swap"

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Tobba611

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2021 PA Special
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Discussion starter · #1 ·
Doing a "tin swap" on a PAS isn't as involved as Street Glide. It's just the tank and fairing. But here it is, going from my "Baja Orange" to a "Billiard Grey.

Special thanks to @kw278, who sold me his tank and fairing. Thanks to his expert packing and careful removal, my new Billiard Grey is perfect. Thanks man!

Started by removing the plastic shroud and then the filler cap. It wasn't necessary to disconnect all of the vacuum lines from the cap, just unbolt and flip it up. Then secure with a bungee or cord.

There is a small two-wire connection to the bottom of the filler for the fuel level switch. Unplugs easily. Then there will be a small clip that holds the float mechanism in place. Lift up slightly and slide it back.

Image


Carefully rotate the float/level sending switch and remove.

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No E-coat:

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Interior e-coat (2024 and up)

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I'm not going to get into removing the tank or swapping the fuel pump here, since there are other posts and even you-tube videos of that.

But here is my fuel pump "filter" after 46,000 miles. Still on the original pump.

Image

I was temped to change the filter here. But no one has one in stock, I'm too impatient to wait for one and I'm going for an eight hour ride tomorrow.

I did hit it with some carb cleaner, but didn't seen anything come out.

Before:

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AND AFTER:

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#5 ·
Looks good and glad it went off without a hitch - glad my "ex" found a new home. I made a couple of mistakes in my swapping exercise - since I tried to remove the fuel cap from the lines (instead of simply flipping it over the handlebar) I ended up shattering the plastic tube at the front of the cap - $150 to correct that, unfortunately. And I assumed that the blue tank I purchased came with the plug installed at the rear of the tank. Discovered it did not when I put a gallon on fuel in the tank and it ended up all over the garage floor!
 
Discussion starter · #7 ·
kw278 said:
Looks good and glad it went off without a hitch - glad my "ex" found a new home. I made a couple of mistakes in my swapping exercise - since I tried to remove the fuel cap from the lines (instead of simply flipping it over the handlebar) I ended up shattering the plastic tube at the front of the cap - $150 to correct that, unfortunately. And I assumed that the blue tank I purchased came with the plug installed at the rear of the tank. Discovered it did not when I put a gallon on fuel in the tank and it ended up all over the garage floor!
Click to expand...
150 bucks for a plastic tube?? Which one?

I knew my Grey tank would be missing the E-coat plug from your sales post. I got the part number from a previous thread you did asking about the number. I stopped by my local shop on my way home the day I bought the tank. The sales manager had one on his freaking keyboard! Three dollars cash.. Everything went smooth..

Except for the torx bolts size.. I only had one bit in my shop that fit right. The t25 seemed too big and the t20 was too small. The only one that fit correctly was my Harley-Davidson branded snap-on screwdriver.
 
#10 ·
Oh, and I eliminated the 'tip over' valve.
I got tired of re-installing it every time I swapped fuel pumps!
 
#11 ·
Tobba611 said:
150 bucks for a plastic tube?? Which one?

I knew my Grey tank would be missing the E-coat plug from your sales post. I got the part number from a previous thread you did asking about the number. I stopped by my local shop on my way home the day I bought the tank. The sales manager had one on his freaking keyboard! Three dollars cash.. Everything went smooth..

Except for the torx bolts size.. I only had one bit in my shop that fit right. The t25 seemed too big and the t20 was too small. The only one that fit correctly was my Harley-Davidson branded snap-on screwdriver.
Click to expand...
"Tube" may be a bit misleading - the fuel cap has a molded tube coming out that the 1 O'Clock position - it's part of the assembly. So when it broke I had to buy a new fuel camp.
 
#12 ·
Tobba611 said:
150 bucks for a plastic tube?? Which one?

I knew my Grey tank would be missing the E-coat plug from your sales post. I got the part number from a previous thread you did asking about the number. I stopped by my local shop on my way home the day I bought the tank. The sales manager had one on his freaking keyboard! Three dollars cash.. Everything went smooth..

Except for the torx bolts size.. I only had one bit in my shop that fit right. The t25 seemed too big and the t20 was too small. The only one that fit correctly was my Harley-Davidson branded snap-on screwdriver.
Click to expand...
As for the plug - as I recall I used one of my standard torx sizes - but I can't remember which one.
 
#13 ·
kw278 said:
"Tube" may be a bit misleading - the fuel cap has a molded tube coming out that the 1 O'Clock position - it's part of the assembly. So when it broke I had to buy a new fuel camp.
Click to expand...
That's the one that broke, I drilled it out and put a brass nipple
 
#14 · (Edited)
Rocket said:
That 'plastic tube' I replaced with a brass nipple when I broke mine off.

View attachment 7814
Click to expand...
Good for you - I should have thought of that.

As a temporary fix I used gorilla glue but knew that it was not permanent. Might try your fix on the old unit just to see - what sized hole and what are the dimensions of the nipple?
 
#15 ·
I think it was 1/8" double barb brass fitting, I sanded down one side and matched the drill bit to fit snug. I went slow but used the theory that "it already broke"
 
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