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 RtSide/Man Rigid - Down (TwistOn-Cap/61102-83C)
92 All 2.25gal RtSide/Man Rigid - Down (ScrewIn-Cap/61272-92)
Option 3.25gal LtSide/Vac Rigid - Down (1992 P&A Catalog Option)
93-94 All 2.25gal RtSide/Man Grommet - Down
Option 3.25gal LtSide/Vac Grommet – Down (1994 P&A Catalog Option)
95 883 2.25gal LtSide/Vac Grommet - Down
1200 3.25gal LtSide/Vac Grommet - Down
96 883 2.25gal LtSide/Vac Grommet - Down
1200 3.3gal LtSide/Vac Grommet – Down (w/RoundedBottomEdge)
97-98 All 3.3gal LtSide/Vac Grommet - Down Primed part # (61348-03)1)
99-03 All 3.3gal LtSide/Vac Grommet - Down
04-06 Std/L/R 3.3gal LtSide/Vac Rigid – Under Seat (883Std&1200R&883L&883R)
8C/12C 4.5gal LtSide/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)

The Petcock allows control of the fuel to the carburetor from the fuel tank. It has a 3-position lever to create OFF, ON & RESERVE settings. The OFF setting prevents fuel flow to the carb (used whenever the bike is not running). The ON setting allows normal fuel flow to the carb when the tank is above the reserve level. The RESERVE setting allows the final amount of fuel to be sent to the carb until the tank is empty. Normally, the petcock has an in-tank cylindrical mesh filter enclosing these inlets to prevent any dirt in the tank from clogging the intake of fuel. The tank and filter may be required to be cleaned from time to time.

The petcock creates two levels of fuel supply in the fuel tank, the higher level being used for the ON setting and a low level being used for the RESERVE supply level. To do this, a short tube protrudes vertically into the fuel supply to create an ON level. A shorter tube (or the base of the petcock) is used to supply fuel ONLY when the petcock is set to RESERVE. By drawing fuel from the taller tube when the petcock is set to ON, a 'reserve' is created (usually between 20% & 30% of the tank size) below that tube level so as to warn the rider that the tank is running low on fuel.

When the fuel level drops below the level of the taller ON tube, the engine will sputter or die. The rider needs to switch to the RESERVE setting in order to use the final amount of fuel in the tank - and get to a fuel station before running out completely.

2)

Starting in 1992, when there was an option for a 3.25gal Sportster tank, the petcock specified was a new, vacuum-operated design. It had an automatic shutoff function that used a vacuum hose connected to the carburetor (tee'd off the hose to the VOES) to operate a diaphragm in the petcock. This diaphragm had a short plug that protruded into the fuel flow cavity, and held there by a spring, to prevent fuel flow until there was enough vacuum to pull the diaphragm/plug out of the cavity.

This was considered a safety feature to help riders who forgot to turn the petcock to the OFF position (and to help prevent fuel spills in case of an accident or tipover). It was the recommended petcock for all optional tanks from 1992-1994. This style petcock was implemented on all stock tanks (of any size) from 1995 thru 2006 (2007-later used electrical fuel pumps). A vacuum of approximately 0.5-1.0 in. of Mercury (Hg) was needed to open the petcock for fuel flow.3) The OFF setting was still recommended whenever the engine was not running (to prevent accidental fuel flow from a faulty vacuum diaphragm).

Failures:
When the petcock vacuum-diaphragm is cracked or torn, it may not open the fuel flow enough to operate the bike at full speed. The fuel flow will be restricted because the diaphragm will not pull the plug fully out. Also with a faulty diaphragm, it can leak fuel down the vacuum hose to the carb. This creates an overly rich fuel-mix condition.

So, depending on exactly how the petcock fails, you might get a too rich or a too lean condition.

Manual petcocks can also fail. They can leak fuel from the seals. They can collect debri on the filter screens. If the filter fails, it can allow debri into the operating petcock and clog the passages.


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

2005 XL Model Wire Harness Elbow: 4)
If you remove the RH wire harness elbow (73205-05), it is recommended to install washer (6859M) on the mounting bolt when reinstalling the elbow.
This is to prevent future damage to the elbow’s mounting hole.
This washer was installed in production as of February 27, 2005.



1)
1998 HD HLH Parts Catalog
2)
drawing by Hippysmack
3)
2006 Factory Service Manual
4)
HD TECH Tip (TT059) dated May 5, 2009
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