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--- techtalk:evo:oil04g [2021/02/28 20:37]
hippysmack [Pics and Information on 1986-2003 Sportster Oil Tanks]
+++ techtalk:evo:oil04g [2024/01/05 19:06] (current)
hippysmack
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 ====== EVO: Oiling & Lubrication - Sub-04G ======
-====== Pics and Information on 1986-2003 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. \\
+\\
-|  1997-1999 Oil Tank and cover (62475-97). (All models) ((photo by Hippysmack))  |||
+In 2004, the MoCo started using plastic oil tanks. \\
-|{{:techtalk:evo:oil:oil_tank_62475-97_pic_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_tank_62475-97_pic_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_tank_62475-97_pic_3_by_hippysmack.jpg?direct&300|}}|
+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/146231-ka-boom-oil-tank/page4?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 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. \\
+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.. \\
+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/205256-oil-tank#post4647082)). \\
+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/37658-new-oil-tank/page3?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|}}|
+|  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|}}|
+|  2007 1200C with 2010-2013 Oil Tank ((Pics by Captain Johnny of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/205256-oil-tank#post4647082))  |||
+|{{:techtalk:evo:oil:2007_1200c_with_2010-2013_oil_tank_pic1_by_captain_johnny.jpg?direct&300|}}|{{:techtalk:evo:oil:2007_1200c_with_2010-2013_oil_tank_pic2_by_captain_johnny.jpg?direct&300|}}|{{:techtalk:evo:oil:2007_1200c_with_2010-2013_oil_tank_pic3_by_captain_johnny.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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix/page4?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix/page5?t=1566307&page=5))|This shows where the gauge is to start with. ((photo by harley506d of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix/page5?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix/page5?t=1566307&page=5))|This shows final location. ((photo by harley506d of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix/page5?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 ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?t=1566307))|Note the locking tabs on one half of the sleeve and \\ none on the other. ((photo by JohnK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix/page4?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/144466-does-your-oil-filler-cap-pop-out-here-s-a-cheap-and-easy-fix?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 ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?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 ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_8_by_ridinfool.jpg?direct&300|}} ((photo by ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?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 ridinfool https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_2_by_ridinfool.jpg?direct&300|}} ((photo by ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_3_by_ridinfool.jpg?direct&300|}} ((photo by ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?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 ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_5_by_ridinfool.jpg?direct&300|}} ((photo by ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?t=887399)) {{:techtalk:evo:oil:07_up_homemade_oil_temp_cap_6_by_ridinfool.jpg?direct&300|}} ((photo by ridinfool of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/102000-fools-homemade-oil-temp-gauge?t=887399))
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