EVO: Body Parts

FUEL TANKS

☚—————– ALSO CHECK OUT THE TANKS IN THE GAS TANK GALLERY ————-—-☛


82-85 Ironhead tanks are the same as 1986 Evo
Stock Tank Features As Supplied on Different Models
Petcock is Mount is Rigid/Grommet
Year Models TankSize Rt/Lt/Man/Vac RrEars Down/UnderSeat Notes
86-91 All 2.25gal Right/Man Rigid - Down (TwistOn-Cap/61102-83C)
92 All 2.25gal Right/Man Rigid - Down (ScrewIn-Cap/61272-92)
Option 3.25gal Left/Vac Rigid - Down (1992 P&A Catalog Option)
93-94 All 2.25gal Right/Man Grommet - Down
Option 3.25gal Left/Vac Grommet – Down (1994 P&A Catalog Option)
95 883 2.25gal Left/Vac Grommet - Down
1200 3.25gal Left/Vac Grommet - Down
96 883 2.25gal Left/Vac Grommet - Down
1200 3.3gal Left/Vac Grommet – Down (w/RoundedBottomEdge)
97-98 All 3.3gal Left/Vac Grommet - Down Primed part # (61348-03)1)
99-03 All 3.3gal Left/Vac Grommet - Down
04-06 Std/L/R 3.3gal Left/Vac Rigid – Under Seat (883Std&1200R&883L&883R)
8C/12C 4.5gal Left/Vac Rigid - Under Seat (883C&1200C)

Starting in 2007:

  • No petcock - Electronic Fuel Pumps implemented on all tanks
  • Tanks are rigid mounted because engine is rubber-mounted
  • Tanks have rear mount under seat (but different from 04-06)
  • All tanks mount the same 2007-17 - These three primed tanks are available:
    • 2.1gal Prime 61724-10 «-back to 2010
    • 3.3gal Prime 61405-07 «-back to 2007
    • 4.5gal Prime 62213-07 «-back to 2007
Stock Tank Sizes As Supplied on Different Models (All Capacities are in Gallons)
2007 08 09 2010 11 12 13 14 15 16 17 18 19 2020
883 Standard 3.3 3.3 3.3
883L Low/Superlow 3.3 3.3 3.3 3.3 4.5 4.5 4.5 4.5 4.5 4.5 4.5
883C Custom 4.5 4.5 4.5 4.5
883R Roadster 3.3
883N Iron (Nghtsr?) 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
1200N Nightster 3.3 3.3 3.3 3.3 3.3 3.3
1200C Custom 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5
1200L Low 4.5 4.5 4.5 4.5 4.5
1200T SuperlowT 4.5 4.5 4.5 4.5
1200R Roadster 3.3 4.5
1200X Model 48 2.1 2.1 2.1 2.1 2.1 2.1 2.1
1200V Model 72 2.1 2.1 2.1 2.1 2.1 2.1
XR1200/XR1200X 3.5 3.5 3.5 3.5
1200-Model50-Annv 3.3

Notes

Generally, you can _make_ tanks interchange between '82 to '03 - Mounting holes are at the same place, but some are rigid mount & others rubber grommet mount.

Screw-in Caps from 1992-later are generally interchangeable although some part number variations do exist over the various models and years.

All non-efi use 22mm petcocks.

There are adapters available to replace the EFI pump plate with a flat-plate with a petcock bung. This may allow the use of a tank intended for EFI models to be used on carburetored models. See this XLForum Thread.

Reference Threads

http://xlforum.net/forums/showthread.php?t=1969877
http://xlforum.net/forums/showthread.php?t=652141


Petcock (Fuel Outlet)


Vapor Valve (Tank Venting)

From the 2003 Sportster Service Manual

(Fuel Tank section)

“The fuel tank is vented through a standpipe (vent tube) within the tank. A hose at the base of the fuel tank is connected to the standpipe.”

“The fuel tank vapor hose is connected to a vapor valve located beneath the seat between the oil tank and the battery tray. ON non-California models, another hose connects the vapor valve bottom fitting to a hollow frame member. On California models, the bottom hose is routed to the carbon canister.”

“Mount the vapor valve in an upright position with the longer fitting positioned at the top or excessive fuel vapor pressure may build up within the fuel tank.”

(CA EVAP section)

“If the vehicle is tipped at an abnormal angle, the vapor valve closes to prevent liquid gasoline from leaking out of the fuel tank through the vent hose.”


FENDERS



1)
1998 HD HLH Parts Catalog
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