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techtalk:evo:oil04g [2021/02/28 21:17] hippysmack created |
techtalk:evo:oil04g [2023/07/27 17:41] hippysmack [Pics and Information on 2004-2009 Sportster Oil Tanks] |
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====== EVO: Oiling & Lubrication - Sub-04G ====== | ====== EVO: Oiling & Lubrication - Sub-04G ====== | ||
====== Pics and Information on 2004-2009 Sportster Oil Tanks ====== | ====== Pics and Information on 2004-2009 Sportster Oil Tanks ====== | ||
+ | See also in the Sportsterpedia; \\ | ||
+ | ….. *[[techtalk:evo:oil04#oil_line_routing|1986-Up Oil Line Routing]] \\ | ||
+ | ….. *[[techtalk:evo:elec02m#pics_and_information_on_stock_evo_battery_trays_and_parts|Pics and Information on stock EVO Battery Trays and Parts]] | ||
+ | |||
+ | **Note: These tanks are prone to leaking and / or bursting**. \\ | ||
+ | [[techtalk:ref:oil20#up_oil_tank_leak_issue|Click Here]] for more in formation on 2004-Up Oil Tank Leak Issues. \\ | ||
\\ | \\ | ||
- | ====== 2004-2009 ====== | ||
- | In 2004, the MoCo started using plastic oil tanks. There were two factory installed versions, 04-06 (62888-04 ) and 07-09 (62888-04A). \\ | + | In 2004, the MoCo started using plastic oil tanks. \\ |
+ | There were two factory installed versions, 04-06 (62888-04) and 07-09 (62888-04A) for all models except XR1200/XR1200X. \\ | ||
+ | XR1200 and XR1200X models use tank 2007-2009 tank (62888-08) and 2010-2013 tank (62888-08A). \\ | ||
The 04-09 oil tank versions share the same basic setups as the oil tank and electrical junction box (that is vulnerable to moisture). ((Bone of the XLFORUM http://xlforum.net/forums/showthread.php?t=1587844&highlight=62954-10&page=4)) \\ | The 04-09 oil tank versions share the same basic setups as the oil tank and electrical junction box (that is vulnerable to moisture). ((Bone of the XLFORUM http://xlforum.net/forums/showthread.php?t=1587844&highlight=62954-10&page=4)) \\ | ||
The EFI bikes use up more space in the junction box, having an additional relay and more fuses?). \\ | The EFI bikes use up more space in the junction box, having an additional relay and more fuses?). \\ | ||
+ | The 07-09 tank has a less restrictive cavity in the top section than the 04-09 tank to allow more free flowing air back to the cam chest. \\ | ||
Late 2009, they came out with an upgrade version (62888-04B) with a 10 PSI pressure relief valve in the top of the tank, right side. \\ | Late 2009, they came out with an upgrade version (62888-04B) with a 10 PSI pressure relief valve in the top of the tank, right side. \\ | ||
The -04B tank fits 2004-2009 Sportsters and also has a less restrictive vent tube configuration inside the tank. \\ | The -04B tank fits 2004-2009 Sportsters and also has a less restrictive vent tube configuration inside the tank. \\ | ||
+ | However, the -04B has now been obsoleted as well.. \\ | ||
- | | 04-09 Oil Tank Upgrade (62888-04B) ((photos by npaisnel of the XLFORUM http://xlforum.net/forums/showthread.php?t=74331&page=3)) ||| | + | The 2010-2013 oil tank (62954-10) will fit 2004-2009 models (except XR1200/XR1200X) and it also has the 10psi relief valve. ((Captain Johnny of the XLFORUM http://xlforum.net/forums/showthread.php?p=6003148#post6003148)). \\ |
+ | The hose fitting locations changed again so you'll have to reroute the hoses to use this tank on 2004-2009 models. | ||
+ | |||
+ | Click on any pic below to enlarge: \\ | ||
+ | | 2007-2009 Sportster Oil Tank (62888-04A) ((photos by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-Sportster-1200-Low-XL1200L-2007-Oil-Tank-Pan/254870990156?epid=1223284928&hash=item3b577ead4c:g:LKsAAOSw0KJgLSiN|Auction link on date of posting]] )) ||| | ||
+ | |{{:techtalk:evo:oil:2007-2009_sportster_oil_tank_62888-04a_pic1_by_americanbikestrippers.jpg?direct&300|}}|{{:techtalk:evo:oil:2007-2009_sportster_oil_tank_62888-04a_pic2_by_americanbikestrippers.jpg?direct&300|}}|{{:techtalk:evo:oil:2007-2009_sportster_oil_tank_62888-04a_pic3_by_americanbikestrippers.jpg?direct&300|}}| | ||
+ | |||
+ | | 2004-2009 Oil Tank Upgrade (62888-04B) ((photos by npaisnel of the XLFORUM http://xlforum.net/forums/showthread.php?t=74331&page=3)) ||| | ||
|{{:techtalk:evo:oil:04-09_xl_oil_tank_62888-04b_pic1_by_npaisnel.jpg?direct&300|}}|{{:techtalk:evo:oil:04-09_xl_oil_tank_62888-04b_pic2_by_npaisnel.jpg?direct&300|}}|{{:techtalk:evo:oil:04-09_xl_oil_tank_62888-04b_pic3_by_npaisnel.jpg?direct&300|}}| | |{{:techtalk:evo:oil:04-09_xl_oil_tank_62888-04b_pic1_by_npaisnel.jpg?direct&300|}}|{{:techtalk:evo:oil:04-09_xl_oil_tank_62888-04b_pic2_by_npaisnel.jpg?direct&300|}}|{{:techtalk:evo:oil:04-09_xl_oil_tank_62888-04b_pic3_by_npaisnel.jpg?direct&300|}}| | ||
+ | | More Oil Tank (62888-04B) Pics ((photos courtesy of BIKERSNOS.com. [[https://www.ebay.com/str/bikersnos?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) ||| | ||
+ | |{{:techtalk:evo:oil:2004-2009_sportster_oil_tank_upgrade_62888-04b_pic1_by_bikersnos.jpg?direct&300|}}|{{:techtalk:evo:oil:2004-2009_sportster_oil_tank_upgrade_62888-04b_pic2_by_bikersnos.jpg?direct&300|}}|{{:techtalk:evo:oil:2004-2009_sportster_oil_tank_upgrade_62888-04b_pic3_by_bikersnos.jpg?direct&300|}}| | ||
+ | |||
+ | ====== Oil Cap ====== | ||
+ | \\ | ||
+ | ===== 04+ Oil Cap ===== | ||
+ | These can be stubborn to turn all the way. You can use a little silicone lube on the O-ring to help it turn without binding. \\ | ||
+ | Also a leather glove for grip helps. ((JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=4)) \\ | ||
+ | The threading tabs in the tank are molded in. \\ | ||
+ | |||
+ | When installing the cap, it may stop at the first "bite" and not go any farther. The plastic cap has a void underneath which gives no support. \\ | ||
+ | If the cap is difficult to turn in, it may have been inserted in the wrong position. \\ | ||
+ | First, try to remove it and make sure the tab orientation is correct before re-inserting it in the tank (else it won't turn all the way 'home' and seal off the tank). \\ | ||
+ | |||
+ | The metal cap with the analog gauge moves better as it is solid underneath the rim. \\ | ||
+ | |||
+ | The pics below show the positions of the cap during installation.: | ||
+ | |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 Cap Repair ====== | ||
+ | |||
+ | ===== 04 Style Oil Cap Repair ===== | ||
+ | Article by JohnK of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=1566307)) \\ | ||
+ | |||
+ | If you've noticed your oil cap mysteriously popping up, it could be a broken internal sleeve. \\ | ||
+ | One of the first symptoms is that the cap will not stay flush, but will protrude maybe an eighth of an inch above the tank surface. \\ | ||
+ | Eventually it will not click down in place at all. \\ | ||
+ | Take a close look just under the cap, where the plunger enters the body. \\ | ||
+ | The black sleeve protruding above the grey body (in the right side arrow in the 1st pic below) may indicate a broken sleeve. \\ | ||
+ | |||
+ | |The sleeve should be flush around the perimeter as \\ shown by the left side arrow. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|To disassemble, find the two side square tabs and \\ push each one in, and the mechanism will pop out \\ under spring pressure. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))| This is what you will have, notice the ratchet spring \\ on the side, note how it fits for re-assembly later. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))| | ||
+ | |{{:techtalk:evo:oil:oil_cap_repair_1_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_2_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_3_by_johnk.jpg?direct&300|}}| | ||
+ | |||
+ | Now take a look at the bottom of the 'sleeve'. \\ | ||
+ | It should be one piece. \\ | ||
+ | The two halves are held together by two very thin sections of plastic on the bottom (as in the circled areas below). \\ | ||
+ | In this case, the sleeve was broken into two pieces. \\ | ||
+ | |||
+ | The locking tabs are both on one half of the sleeve, the other side is free to slide inside the body. \\ | ||
+ | As long as the sleeve is joined together in one piece that's fine. \\ | ||
+ | But the bottom thin section is prone to cracking. \\ | ||
+ | (one side is locked and the other moves up and down ever so slightly each time the cap is popped) \\ | ||
+ | Once this fails, the 'loose' side will protrude up as seen in the first pic above. \\ | ||
+ | The side without the locking tabs is also the side with the ratchet spring. \\ | ||
+ | (which adds additional up and down drag every time the mechanism is worked, accelerating the failure) \\ | ||
+ | |||
+ | |The thin connecting material was broken out. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|Here are all the components, minus the broken out \\ pieces. The sleeve is now in two halves. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|Note the locking tabs on one half of the sleeve and \\ none on the other. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))| | ||
+ | |{{:techtalk:evo:oil:oil_cap_repair_4_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_5_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_6_by_johnk.jpg?direct&300|}}| | ||
+ | |||
+ | The solution was to re-assemble the mechanism and install a set-screw to hold the loose side in place. \\ | ||
+ | |||
+ | The entire operation shouldn't take more than an hour, if you take your time. \\ | ||
+ | The only items required are a small screwdriver to push in the locking tabs, a set screw, an appropriate drill bit and drill. \\ | ||
+ | You can find a small flat head screw, countersink the hole and drive the screw head flush for a better-than original look and function. \\ | ||
+ | {{:techtalk:evo:oil:oil_cap_repair_1_by_samjmm.jpg?direct&300|}} ((photo by samjmm of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=4)) \\ | ||
+ | |||
+ | Below, a brass screw from an electrical lug was used to screw through the grey plastic body and into the black inner sleeve. \\ | ||
+ | It was short enough not to interfere with the moving plunger while long enough to screw through the grey plastic body to the sleeve. \\ | ||
+ | Find a way to hold the sleeve down flush with the outer body and drill a hole slightly smaller than the screw thread. \\ | ||
+ | Drill it right through both the body and sleeve. \\ | ||
+ | It can be done with the plunger installed but it would be better to leave it out. \\ | ||
+ | Drive the screw into the plastic, it will cut its own thread (that's why you drill a smaller pre-drill size hole). \\ | ||
+ | |||
+ | |Finished product. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|Here's what it looks like from the inside. The spot for this particle drilled hole put the screw partially in the slot, \\ which would have nullified the fix. A smarter choice would have been into one of the lugs as indicated below. ((photos by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|| | ||
+ | |{{:techtalk:evo:oil:oil_cap_repair_7_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_8_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_9_by_johnk.jpg?direct&300|}}| | ||
+ | |||
+ | ===== 07 Style Oil Cap with Homemade Temperature Gauge ===== | ||
+ | Article by ridinfool of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=887399)) | ||
+ | |||
+ | Sometimes you have to be innovative to save some cash. \\ | ||
+ | This oil temp gauge was devised for about $20 as opposed to the $45 one from the MoCo. \\ | ||
+ | |||
+ | {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_7_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_8_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) | ||
+ | |||
+ | Parts & Tools: \\ | ||
+ | One meat thermometer either instant read dial or digit read. \\ | ||
+ | Some JB Weld. \\ | ||
+ | Drill / bit. | ||
+ | |||
+ | Take the oil cap apart as shown below. \\ | ||
+ | Then cut the dipstick off flush with bottom of the cap. \\ | ||
+ | |||
+ | {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_1_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_2_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_3_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) | ||
+ | |||
+ | Drill a hole just a bit smaller than the thermometer rod through the center so it fits snug. \\ | ||
+ | Then drill a hole through the top of the oil cap. \\ | ||
+ | Going through the bottom, there is a plastic piece that guides the drill bit. \\ | ||
+ | Slide the meat thermometer in place with some JB weld on the bottom of it so it stays in place. \\ | ||
+ | (make sure not to get the JB Weld on the rod itself as it needs to go up and down with the oil cap) \\ | ||
+ | |||
+ | {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_4_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_5_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_6_by_ridinfool.jpg?direct&300|}} ((photo by http://xlforum.net/forums/showthread.php?t=887399)) | ||