See also in the Sportsterpedia;
….. *1986-Up Oil Line Routing
….. *Pics and Information on stock EVO Battery Trays and Parts

Click on any pic below to enlarge:

Starting in 1994, the starter relay (31504-91A) was moved away from the oil tank and riveted to the electrical bracket with a 3/16“ x 7/16” x 5/8“ pop rivet.
The threaded hole continued to be added to future oil tanks thru 1999. So 1994-1999 oil tanks will interchange.
The threaded hole for the starter relay was deleted on 2000-2003 oil tanks. Instead the MoCo added a welded stud for a plastic clip.
2000-2003 oil tanks will retro to 1994 applications with the exception of needing an alternative mounting place for the starter relay.

1994-1996 Mounts 1)	1997-2003 Mounts 2)

Used oil tank below.

^{3) 4)}

^{5) 6) 7)}

The 97-99 oil tank looks exactly like the 96 tank with the exception of a wider bracket welded to the top for a wiring clip holder.
Also the feed / drain nipple on the back of the tank is angled toward the front to gain some room between the hose and frame.
It still has the threaded hole on the upper rear wall for use with earlier models.

1997-1999 Oil Tank and cover (62475-97). (All models) 8)

⁹⁾ | ^{10) 11)}

This is the replacement oil tank for 1994-1999 models. It is also the tank that was made available for the now obsolete 82-93 oil tank retro kit.
However, the 94-97 battery tray is needed to use this tank for upgrade to 82-93 models.
It looks identical to the 2000-2003 oil tank and bracing but it also has an added threaded hole in the back for mounting the starter relay to 82-93 models.
The OEM 2000-2003 oil tanks do not have that threaded hole.

Used oil tank below.

^{12) 13) 14)}

Used oil tank below.

^{15) 16) 17)}

^{18) 19) 20)}

OEM oil cap for 97-03 Sportster Oil Tanks:
^{21) 22) 23)}

The hole in the tank for the oil cap is tapered.
The top of the taper is app. 1.274” and the bottom of the taper is app. 1.224“.

97-03 Oil Cap Hole in Tank Dims 24)

Analog dipstick with temp gauge (62667-87TA) chrome-plated cap with Harley-Davidson script on the face.
^{25) 26) 27)}

This one from a 2001 1200S model was leaking from the area of the bottom stud. The metal near the stud was cracked and the stud loose where it was welded.
You can use a very large heavy duty washer that fits over the stud and weld it on to reinforce the area after first cleaning it and repairing the original crack. ²⁸⁾

^{29) 30)}