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| techtalk:ih:oil04m [2021/03/29 16:53] – [Revised Kit] hippysmack | techtalk:ih:oil04m [2025/06/20 18:07] (current) – [1982-1993 Sportster Retrofit Oil Tank Kit (except XR-1000)] hippysmack |
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| ====== 1982-1993 Sportster Retrofit Oil Tank Kit (except XR-1000) ====== | ====== 1982-1993 Sportster Retrofit Oil Tank Kit (except XR-1000) ====== |
| See also in the Sportsterpedia; \\ | See also in the Sportsterpedia;\\ |
| ….. *[[techtalk:ih:oil04#oil_line_routing|57-85 Oil Line Routing]] \\ | ….. *[[:techtalk:ih:oil04#oil_line_routing|57-85 Oil Line Routing]]\\ |
| ….. *[[techtalk:evo:oil04#oil_line_routing|1986-Up Oil Line Routing]] \\ | ….. *[[:techtalk:evo:oil04#oil_line_routing|1986-Up Oil Line Routing]]\\ |
| ….. *[[techtalk:ih:elec02m#pics_and_information_on_stock_ih_battery_trays_and_parts|Pics and Information on stock IH Battery Trays and Parts]] \\ | ….. *[[:techtalk:ih:elec02m#pics_and_information_on_stock_ih_battery_trays_and_parts|Pics and Information on stock IH Battery Trays and Parts]]\\ |
| ….. *[[techtalk:evo:elec02m#pics_and_information_on_stock_evo_battery_trays_and_parts|Pics and Information on stock EVO Battery Trays and Parts]] | ….. *[[:techtalk:evo:elec02m#pics_and_information_on_stock_evo_battery_trays_and_parts|Pics and Information on stock EVO Battery Trays and Parts]] |
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| Note, these can still be found used online, Ebay, etc. A special thanks to Rusty Dusty Motorcycle Parts for the pics below. \\ | Note, these can still be found used online, Ebay, etc. A special thanks to Rusty Dusty Motorcycle Parts for the pics below. \\ |
| You can see the reinforced bracing while still using a 2 hole mount battery tray. \\ | You can see the reinforced bracing while still using a 2 hole mount battery tray. \\ |
| | Used oil tank below. \\ |
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| {{:techtalk:evo:oil:1983-1993_sportster_oil_tank_upgrade_pic1_by_rusty_dusty_parts.jpg?direct&300|}} ((photo courtesy of Ebay seller, rusty_dusty_parts, store: [[https://www.ebay.com/str/bialystreasures|Ebay store link:]] )) {{:techtalk:evo:oil:1983-1993_sportster_oil_tank_upgrade_pic2_by_rusty_dusty_parts.jpg?direct&300|}} ((photo courtesy of Ebay seller, rusty_dusty_parts, store: [[https://www.ebay.com/str/bialystreasures|Ebay store link:]] )) {{:techtalk:evo:oil:1983-1993_sportster_oil_tank_upgrade_pic3_by_rusty_dusty_parts.jpg?direct&300|}} ((photo courtesy of Ebay seller, rusty_dusty_parts, store: [[https://www.ebay.com/str/bialystreasures|Ebay store link:]] )) \\ | {{:techtalk:evo:oil:1983-1993_sportster_oil_tank_upgrade_pic1_by_rusty_dusty_parts.jpg?direct&300|}} ((photo courtesy of Ebay seller, rusty_dusty_parts, store: [[https://www.ebay.com/str/bialystreasures|Ebay store link:]] )) {{:techtalk:evo:oil:1983-1993_sportster_oil_tank_upgrade_pic2_by_rusty_dusty_parts.jpg?direct&300|}} ((photo courtesy of Ebay seller, rusty_dusty_parts, store: [[https://www.ebay.com/str/bialystreasures|Ebay store link:]] )) {{:techtalk:evo:oil:1983-1993_sportster_oil_tank_upgrade_pic3_by_rusty_dusty_parts.jpg?direct&300|}} ((photo courtesy of Ebay seller, rusty_dusty_parts, store: [[https://www.ebay.com/str/bialystreasures|Ebay store link:]] )) \\ |
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| For 86-90 models, the 94 upgrade has almost double the distance between supports for the battery tray. \\ | For 86-90 models, the 94 upgrade has almost double the distance between supports for the battery tray. \\ |
| It offers more reinforcement of the tank, the hose routing is much cleaner and the revised battery cables are less prone to failing. ((Four Speed of the XLFORUM http://xlforum.net/forums/showthread.php?p=5873007&highlight=tank+battery#post5873007)) \\ | It offers more reinforcement of the tank, the hose routing is much cleaner and the revised battery cables are less prone to failing. ((Four Speed of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/183021-1986-90-evo-sportsters-what-every-owner-should-know-but-were-afraid-to-ask/page30?highlight=tank+battery#post4468596)) \\ |
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| This kit uses the 94-97 style battery tray (in particular, the 97 tray with the added rubber bumpers , 66194-94A) and oil tank (62475-97A). \\ | This kit uses the 94-97 style battery tray (in particular, the 97 tray with the added rubber bumpers , 66194-94A) and oil tank (62475-97A). \\ |
| This oil tank is the revised version of and replacement for 94-99 oil tanks. \\ | |
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| Using the kit, this is how the drain hose terminates for 93 and earlier setups. \\ | |Part|Quantity|Description|Part|Quantity|Description| |
| | |3930A|3|5/16-18 x 3/4" bolt|44438-82A|1|Brake line assembly (Kit 62482-93A)| |
| | |4092|1|Brake hose bracket screw|Not Sold Separately|1|Brake line asssembly (Kit 62472-93A)| |
| | |7041|1|Lockwasher for brake hose screw|47403-75A|2|Battery tray pad| |
| | |8102|1|Clipnut for brake hose mounting|62475-97A|1|Oil tank assembly| |
| | |6073|3|Spacer washer for left side cover|62493-89|1|Tee fitting (1/2"x1/2"x3/8")| |
| | |6702|3|Washer for screw (battery tray to tank)|62494-94B|1|90° plastic elbow| |
| | |7686|3|1/4-20 x 5/16" x 7/16" locknut \\ (oil tank rubber mount to frame)|62540-83|4|Trim strip| |
| | |7739|1|Locknut (battery tray rubbermount to frame)|62563-65|3|Rubber mount for oil tank| |
| | |10014|1|Feed hose to tank clamp|62569-94|1|Rubber mount for battery tray| |
| | |10039|1|Cable tie strap|62725-90|1|Plastic oil drain plug| |
| | |10049|1|Corbin clamp (drain hose termination)|63504-94|1|Preformed 1/2" drain hose (tee to plug)| |
| | |10080|2|3/8" hose clamp (feed hose from tee to oil pump)|63542-94A|1|1/2" x 8" hose (90° elbow to tee)| |
| | |10108|1|Vapor valve hose clip|63564-94A|1|1/2" x 3" hose (oil tank to 90° elbow)| |
| | |10142|5|1/2" hose clamp|66194-94A|1|Battery Tray| |
| | |41731-82|4|Banjo washer, copper/zinc|70079-94|1|Battery cable assembly| |
| | |41731-88A|4|Banjo washer, steel/rubber|10006|1|Cable strap assembly| |
| | |63576-95|1|Plastic heat shield for hose|||| |
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| | Using the kit, below is the battery tray, feed / drain hose assembly and the drain hose plug for 93 and earlier setups. \\ |
| | The battery tray attaches to the oil tank with three screws. \\ |
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| | | 1997 battery tray. ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] )) | Oil feed and drain hose ((photo by Matt Black of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/192979-1995-oil-lines-obsolete?t=2067584)) | Feed / drain hose assembly. ((photo by chris16371 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/lubrication-and-lubricants/185512-oil-drain-hose?t=1985862)) | |
| | |{{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic1.jpg?direct&300|}}|{{:techtalk:evo:oil:1994-2003_sportster_oil_feed_and_drain_hose_by_matt_black.jpg?direct&300|}}|{{:techtalk:ih:oil:1982-1993_sportster_retrofit_oil_tank_kit_drain_hose_by_chris16371.jpg?direct&300|}}| |
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| | This is the oil tank (62475-97A) in the second 82-93 upgrade kit and is also the revised version of and replacement for 94-99 oil tanks. \\ |
| | It looks identical to the 2000-2003 oil tank but it has an added threaded hole in the back for mounting the starter relay where 00-03 tanks do not have that hole. \\ |
| | Used oil tank below. \\ |
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| | {{:techtalk:ih:oil:1994-1998_sportster_oil_tank_new_version_62472-93a_pic1_by_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Cycle Warehouse https://cyclewarehouse.online/ (Ebay seller cyclewarehouse) )) {{:techtalk:ih:oil:1994-1998_sportster_oil_tank_new_version_62472-93a_pic2_by_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Cycle Warehouse https://cyclewarehouse.online/ (Ebay seller cyclewarehouse) )) {{:techtalk:ih:oil:1994-1998_sportster_oil_tank_new_version_62472-93a_pic3_by_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Cycle Warehouse https://cyclewarehouse.online/ (Ebay seller cyclewarehouse) )) \\ |
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| | {{:techtalk:ih:oil:1994-1998_sportster_oil_tank_new_version_62472-93a_pic4_by_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Cycle Warehouse https://cyclewarehouse.online/ (Ebay seller cyclewarehouse) )) {{:techtalk:ih:oil:1994-1998_sportster_oil_tank_new_version_62472-93a_pic5_by_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Cycle Warehouse https://cyclewarehouse.online/ (Ebay seller cyclewarehouse) )) {{:techtalk:ih:oil:1994-1998_sportster_oil_tank_new_version_62472-93a_pic6_by_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Cycle Warehouse https://cyclewarehouse.online/ (Ebay seller cyclewarehouse) )) |
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| {{:techtalk:ih:oil:1982-1993_sportster_retrofit_oil_tank_kit_drain_hose_by_chris16371.jpg?direct&300|}} ((photo by chris16371 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1985862)) \\ | |
| ====== Alternative to the Retrofit Tank Kit ====== | ====== Alternative to the Retrofit Tank Kit ====== |
| Article by Benton of the XLFORUM to replace a 1988 oil tank. ((http://xlforum.net/forums/showthread.php?t=1564028)) \\ | Article by Benton of the XLFORUM to replace a 1988 oil tank. ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144274-fixing-oil-tank-leak-on-86-93-sportsters?t=1564028)) \\ |
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| J&P carries a battery tray (350-065) for around 100 bucks. The tray fits the 1994 style tank then purchase a 1994 style tank. \\ | J&P carries a battery tray (350-065) for around 100 bucks. The tray fits the 1994 style tank then purchase a 1994 style tank. \\ |
