Tank Assembly per Year Model: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32)
Year | Model | Tank Part # | Oil Cap | Battery Tray |
1983-1993 | All | 62475-83 | 62595-82A | 66191-83 |
1982-1993 | All except XR-1000 | 62475-97A (98 tank) | 62634-84A | 66194-94A (97) |
Notes: | Retrofit oil tank kit with battery box, oil lines and fittings. See the link above under sub documents (1982-1993 Sportster Retrofit Oil Tank Kit) for more information. |
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1994-1996 | All | 62475-94 | 62595-82A | 66194-94 |
1997-1998 | All | 62475-97 62475-97A (2013) | 62634-84A | 66194-94A (97) 66194-98 (98) |
1999 | All | 62475-97 | 62634-84A | 66194-98 |
2000-2003 | All (except 883R) | 62888-99 | 62634-84A | 66194-98 |
883R | 62951-02 (black) | |||
2004-2006 | All | 62888-04 62888-04B (10psi relief valve) | 63000-04 63000-04A (2006) | 66194-04 66194-04B (2006) |
2007-2009 | All (except XR1200) | 62888-04A 62888-04B (10psi relief valve) 62954-10 (requires hose reroute) | 63000-04A 63000-04B (2009) | 66194-04C |
07-08 1200N | 62592-07 | |||
09 883N/1200N | 62592-07A | |||
XR1200/XR1200X | 62888-08 | 63008-08 | ||
2010-2013 | All (except XR1200/XR1200X) | 62954-10 (10psi relief valve) | 63000-04B | 66194-04D |
883N/1200N | 62592-07A | |||
XR1200/XR1200X | 62888-08A | 63008-08 | ||
2014-2022 | All | 62500017 | 63000-04B | 66000031 |
883N | 62592-07A |
Simplified Oil Line Routing Drawings: 35)
Click on a drawing to enlarge:
1994-2003 Oil Feed and Drain Lines 38) | |
HD Part numbers for 1994-2003 Oil Line Hoses: | |
63564-94 | Oil feed / drain hose from tank to 90° elbow, 1/2” I.D. |
62494-94A | 62494-94B 1/2“ plastic 90° elbow |
63542-94A | Oil feed/drain hose from 90° elbow to tee, 1/2” I.D. |
63576-95 | 1“ plastic corrugated hose shield |
62493-89 | 1/2” x 3/8“ x 1/2” plastic tee |
63504-94 | Oil drain hose from tee to block off plug behind rear tube, 1/2“ I.D. |
63500-68 | Oil feed hose from tee to oil pump, 3/8” I.D. x 5/8“ O.D. (25 foot length - cut to fit) |
62631-91 | Oil feed hose from oil pump to oil filter |
62361-94 | Oil return hose from oil pump to oil tank, 3/8” I.D. |
63501-68A | Vent hose, oil tank to cam chest, 1/4“ I.D. x 1/2” O.D. (25 foot length - cut to fit) |
See this XLForum thread regarding 1994-2003 Oil Lines (replacement)
(http://xlforum.net/forums/showthread.php?t=2078814 Post#144)
See the full article, Oil Tank Pressure, in the REF section of the Sportsterpedia.
There should not be any noticeable pressure in the oil tank.
During normal operation;
With the tank cap / dipstick removed, tank pressure is vented to atmosphere from the top of the tank.
With the tank cap / dipstick installed, tank pressure is vented to the cam chest via a hose connecting the two.
During shutdown;
The oil tank vent is connected to the cam chest and the cam chest is vented out the breather valve(s) in the cam cover or heads, respectively.
So if you have pressure in your oil tank and the vent to the cam chest is not blocked then the cam chest is also pressurized.
If the cam chest is holding pressure, then your breather valve(s) can not be venting properly.
Bottom line is that if the vent system is working properly, you shouldn't have excessive pressure build up in the oil tank. 40)
The vent is the right angle nipple fitting on top of the tank (1/4“ hose fitting).
The return is the upper right angle nipple on the back side (3/8” hose fitting).
The feed is the right angle nipple on the bottom of the tank (3/8“ hose fitting).
The drain is the bigger straight nipple on the back near the bottom of the tank (1/2” hose fitting).
Be careful of the feed line on 94-03 models as the FSM diagram is mis-leading. 42)
Feed comes off the oil pump with a 3/8“ hose running under the engine to a 1/2” x 1/2“ x 3/8” tee, a 1/2“ hose to the drain and a 1/2” hose to the tank from the tee.
The vent is the upper right angle nipple fitting on the bottom of the tank (1/4“ hose fitting).
The return is the lower right angle nipple fitting on the bottom of the tank (3/8” hose fitting).
The feed and drain use the same hose and it's the larger upper straight nipple on the back side of the tank (1/2“ hose fitting).
The drain is connected to one side of the tee around to the steel plug nipple on the rear of the frame under the swingarm.
Fittings are labeled in the pics below.
Oil filter connections. 49) |
Periodically inspect all your oil hose connections for leaks or cracks / deteriation, especially before long rides.
There is a dedicated drain hose from the oil tank.
It comes out from the tank, makes a 90 degree bend to the rear and fits into a cylindrical plug welded to the underside of the battery tray.
(on the rear part of the tray, near where the battery strap is fastened) 51)
You should see the oil feed fitting on the bottom of the tank from the chain guard side.
The drain fitting is at the bottom of the sheet metal that forms the back of the tank.
There is a tee in the feed hose (near the frame on the left side of the bike) and the drain hose comes off that tee.
There is a steel plug welded to the rear of the frame under the swingarm.
The drain hose fits over that plug with a worm clamp to hold it there.
You can use auto (fuel) hose from the local car parts store drain hose replacement.
If you cut it the right length, you can bend it without kinking it.
Kinking the hose will not change the flow or anything but may show up as a leak later as the hose ages.
There is a plastic clamp (33123-04) from the bottom frame rail that has a hollow stud for the oil tank drain hose to clamp onto.
The drain hose is anchored up inside the lower rails.
The MoCo eliminated the clamp itself and went to a solid plastic plug (33123-06). 58)
It has a small head that hose clamps into the drain hose and dangles between the bottom frame rails.
It just barely peeks below the frame rails. You can cut the hose a little shorter so it doesn't hang too far below the rails 59)
Drain plug location on an 06 883 60) | ||
The plastic plug was updated (33123-06A).
09-up oil tank drain plug 61) |