EVO: Oiling & Lubrication - Sportsterpedia

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====== EVO: Oiling & Lubrication ======
====== Oil Tank, Lines and Routing ======

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====== Oil Cap ======
===== Sub Documents =====
  * [[techtalk:evo:oil04b|04 Style Oil Cap Repair]] (fix for symptoms of the cap popping out of the tank). \\


===== 04+ Oil Cap =====

|This shows the broader of the 2 locating pegs in the \\ oil tank. ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=5))|This shows where the gauge is to start with. ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=5))|
|{{:techtalk:evo:oil:installing_oil_tank_cap_1_by_harley506d.jpg?direct&300|}}|{{:techtalk:evo:oil:installing_oil_tank_cap_2_by_harley506d.jpg?direct&300|}}|

|This shows the point of "first bite". ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=5))|This shows final location. ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=5))|
|{{:techtalk:evo:oil:installing_oil_tank_cap_3_by_harley506d.jpg?direct&300|}}|{{:techtalk:evo:oil:installing_oil_tank_cap_4_by_harley506d.jpg?direct&300|}}|

====== Oil Tank Pics ======

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====== Oil Tank Pressure ======
See the full article, [[techtalk:ref:oil04#oil_tank_pressure|Oil Tank Pressure]], in the REF section of the Sportsterpedia. \\
There should not be any noticeable pressure in the oil tank. \\

**During normal operation**; \\
With the tank cap / dipstick removed, tank pressure is vented to atmosphere from the top of the tank. \\ 
With the tank cap / dipstick installed, tank pressure is vented to the cam chest. \\

**During shutdown**; \\
The oil tank vent is connected to the cam chest and the cam chest is vented out the breather valve(s) in the cam cover or heads, respectively. \\
So if you have pressure in your oil tank and the vent to the cam chest is not blocked then the cam chest is also pressurized. \\
If the cam chest is holding pressure, then your breather valve(s) can not be venting properly. \\

Bottom line is that if the vent system is working properly, you shouldn't have excessive pressure build up in the oil tank. ((Deimus of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313)) \\

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====== Fittings ======

===== At the Oil Tank =====
Be careful of the feed line on 94-03 models as the FSM diagram is mis-leading. ((Hippysmack)) \\
Feed comes off the oil pump, under the engine, tees to the drain and up to tank. \\
The oil pump scavenger (return) is on the top of the oil pump at the front fitting.\\
On the tank, the feed is the big nipple (1/2") on the back side. ((Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?s=1805bf492596d317acbd024af1df75fa&p=5345059)) \\
The return and vent lines are on the side of the tank facing the front of the bike. \\


Oil hose sizes: ((hidollartoys of the XLFORUM http://xlforum.net/forums/showthread.php?t=947419)) \\
Feed hose: 1/2 " at tank but changes to 3/8" prior to pump. \\
Return hose: 3/8" from pump to tank. \\
Vent hose: 1/4" from cam chest fitting to tank. \\

In the pics below; ((Hot Rod Sporty of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=148936)) \\

  * A is the drain
  * B is the feed
  * C is the vent
  * D is the return

|  94-03 Oil Tank Fittings ((photo by AnaChris of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?postid=5214735))  |  2004-2009 Oil Tank Fittings ((photo by Dragonis of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=148936))  |  2014 and Up Oil Tank Fittings ((photo by Revolver944 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5373531 labeled by Hippysmack))  | 
|{{:techtalk:evo:oil:94-03_oil_tank_by_anachris.jpg?direct&300|}}|{{:techtalk:evo:oil:05_oil_tank_fittings_by_dragonis.jpg?direct&300|}}|{{:techtalk:evo:oil:2014_oil_tank_by_revolver944.jpg?direct&200|}}|


===== At the Oil Pump =====
Fittings are labeled in the pics below. \\

|  86-90 oil pump fittings labeled. ((photo by Hippysmack))  |  91 and Up oil pump fittings labeled ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?s=1805bf492596d317acbd024af1df75fa&p=5345059))  |
|{{:techtalk:evo:oil:86-90_oil_pump_oiling_paths_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:02_oil_pump_by_scuba10jdl.jpg?direct&300|}}|



===== At the Filter Pad =====
==== 1986-1990 ====
|  Oil filter connections. ((photo by Hippysmack))  |
|{{:techtalk:evo:oil:86-90_oil_filter_mount_2_by_hippysmack.jpg?direct&300|}}|


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====== Drain Hose Locations per Year Model ======
===== 86-93 models =====
There is a dedicated drain hose from the oil tank. \\
It comes out from the tank, makes a 90 degree bend to the rear and fits into a cylindrical plug welded to the underside of the battery tray. \\
(on the rear part of the tray, near where the batter strap is fastened) ((John Harper of the XLFORUM http://xlforum.net/forums/showthread.php?t=1985862)) \\
You should see the oil feed fitting on the bottom of the tank from the chain guard side. \\
The drain fitting is at the bottom of the sheet metal that forms the back of the tank. \\

|{{:techtalk:evo:oil:1989_xlh_1200_engine_oil_drain_hose_by_rokkenroll.jpg?direct&300|}}|
|  Engine oil drain hose location on a 1989 XLH 1200 ((photo by RökkenRöll of the XLFORUM http://xlforum.net/forums/showthread.php?t=2069295))  |

===== 94-03 models =====
There is a tee in the feed hose (near the frame on the left side of the bike) and the drain hose comes off that tee. \\
There is a steel plug welded to the rear of the frame under the swingarm. \\
The drain hose fits over that plug with a worm clamp to hold it there. \\

|{{:techtalk:evo:oil:oil_return_and_drain_hose_by_matt_black.jpg?direct&300|}}|{{:techtalk:evo:oil:1998_1200s_engine_oil_drain_hose_by_hippysmack.jpg?direct&300|}}|
|  Oil feed and drain hose ((photo by Matt Black of the XLFORUM http://xlforum.net/forums/showthread.php?t=2067584))  |   Engine oil drain hose location on a 1998 1200S ((photo by Hippysmack))  |

===== 04-05 models =====
==== Sub Documents ====
  * [[techtalk:evo:oil04a|04-05 Oil Drain Plug Mods]]

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There is a plastic clamp (33123-04) from the bottom frame rail that has a hollow stud for the oil tank drain hose to clamp onto. \\
The drain hose is anchored up inside the lower rails. \\

|{{:techtalk:evo:oil:05_drain_hose_clamp_1_by_harley506d.jpg?direct&300|}}|{{:techtalk:evo:oil:05_drain_hose_clamp_2_by_harley506d.jpg?direct&300|}}|{{:techtalk:evo:oil:04_oil_drain_clamp_by_bsaman.jpg?direct&300|}}|
|  Drain clamp on 04-05 models ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072273&page=3))  ||  Wider view ((photo by bsaman of the XLFORUM http://xlforum.net/forums/showthread.php?t=691283&page=2))  |


===== 06-Up models =====
The MoCo eliminated the clamp itself and went to a solid plastic plug (33123-06). ((sportsterpaul of the XLFORUM http://xlforum.net/forums/showthread.php?t=1232772&highlight=frame+clamp&page=46)) \\
It has a small head that hose clamps into the drain hose and dangles between the bottom frame rails. \\
It just barely peeks below the frame rails. You can cut the hose a little shorter so it doesn't hang too far below the rails ((CitySlicker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1232772&highlight=frame+clamp&page=47)) \\

|  Drain plug location on an 06 883 ((photos by southflasportster of the XLFORUM http://xlforum.net/forums/showthread.php?t=463361&page=2))  |||
|{{:techtalk:evo:oil:06_oil_drain_plug_location_1_by_southflasportster.jpg?direct&300|}}|{{:techtalk:evo:oil:06_oil_drain_plug_location_2_by_southflasportster.jpg?direct&300|}}|{{:techtalk:evo:oil:06_oil_drain_plug_location_3_by_southflasportster.jpg?direct&300|}}|

The plastic plug was updated (33123-06A).

|  09-up oil tank drain plug ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?p=5730843#post5730843))  |
|{{:techtalk:evo:oil:09-17_oil_drain_plug_by_harley506d.jpg?direct&300|}}|


===== Drain Hose Mods =====

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Trace: • EVO: Oiling & Lubrication • EVO: Primary Drive & Clutch • W E L C O M E ! • EVO: Oiling & Lubrication • EVO: Carburetor, Intake Manifold & Exhaust • REF: Suspension • IH: Electrical System - Sub-02M • REF: Oiling & Lubrication