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)

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OEM oil cap for 97-03 Sportster Oil Tanks:
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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 18)

Analog dipstick with temp gauge (62667-87TA) chrome-plated cap with Harley-Davidson script on the face.
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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. ²²⁾

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