Table of Contents
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EVO: Oiling & Lubrication - Sub-04F
Pics and Information on 1994-2003 Sportster Oil Tanks
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 Oil Tank
1997-1999 Oil Tank
1997-1999 Oil Tank and cover (62475-97). (All models) 8) | ||
1994-1999 Updated Oil Tank
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.
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.
2000-2003 Oil Tank
97-03 Oil Cap
OEM oil cap for 97-03 Sportster Oil Tanks:
18) 19) 20)
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 21) | |
Analog dipstick with temp gauge (62667-87TA) chrome-plated cap with Harley-Davidson script on the face.
22) 23) 24)
Oil Tank Damage and Repair
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. 25)