Table of Contents
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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)
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: 3)
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.