EVO: Oiling & Lubrication - Sportsterpedia

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====== EVO: Oiling & Lubrication ======
====== Oil Tank, Lines and Routing ======

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====== Oil Cap ======
===== Sub Documents =====
  * [[techtalk:evo:oil04b|04 Style Oil Cap Repair]] (fix for symptoms of the cap popping out of the tank). \\
  * [[techtalk:evo:oil04c|07 Style Oil Cap with Homemade Temperature Gauge]]


===== 97-03 Oil Cap =====
|  97-03 Oil Cap ((photos by Hippysmack))  ||
|{{:techtalk:evo:oil:oil_cap_62634-84a_pic_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_62634-84a_pic_2_by_hippysmack.jpg?direct&300|}}|

|  97-03 Oil Cap ((photos by Hippysmack))  ||
|{{:techtalk:evo:oil:oil_cap_62634-84a_pic_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_62634-84a_pic_4_by_hippysmack.jpg?direct&300|}}|

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 ((photos by Hippysmack))  ||
|{{:techtalk:evo:oil:1998_sportster_oil_tank_cap_hole_dim_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:1998_sportster_oil_tank_cap_hole_dim_2_by_hippysmack.jpg?direct&300|}}| \\
===== 04+ Oil Cap =====
These can be stubborn to turn all the way. ((JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=4)) \\
You can use a little silicone lube on the O-ring to help it turn without binding. \\
Also a leather glove for grip helps. \\
The threading tabs in the tank is 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 Tank Assembly Part Numbers ======

Tank Assembly per Year Model: ((1986 HD Sportster Parts Catalog pg 67)) ((1986-1987 HD Sportster Parts Catalog pg 71)) ((1986-1988 HD Sportster Parts Catalog pg 79)) ((1986-1989 HD Sportster Parts Catalog pg 81)) ((1986-1990 HD Sportster Parts Catalog pg 81)) ((1991 HD Sportster Parts Catalog pg 73)) ((1991-1992 HD Sportster Parts Catalog pg 77)) ((1993 HD Sportster Parts Catalog pg 77)) ((1993-1994 HD Sportster Parts Catalog pg 79)) ((1995 HD Sportster Parts Catalog pg 75)) ((1995-1996 HD Sportster Parts Catalog pg 83)) ((1997 HD Sportster Parts Catalog (98-B) pg 81)) ((1998 HD Sportster Parts Catalog (98-B) pg 85)) ((1999 HD Sportster Parts Catalog (99-A) pg 91)) ((2000 HD Sportster Parts Catalog (00-A) pg 91)) ((2001 HD Sportster Parts Catalog (01-A) pg 93)) ((2002 HD Sportster Parts Catalog pg 93)) ((2003 HD Sportster Parts Catalog pg 93)) ((2004 HD Sportster Parts Catalog (-04) pg 89)) ((2004 HD Sportster Parts Catalog (-04A) pg 91)) ((2005 HD Sportster Parts Catalog pg 93)) ((2006 HD Sportster Parts Catalog pg 93)) ((2007 HD Sportster Parts Catalog pg 99)) ((2008 HD Sportster Parts Catalog pg 99)) ((2009 HD Sportster Parts Catalog pg 151)) ((2010 HD Sportster Parts Catalog pg 149)) ((2011 HD Sportster Parts Catalog pg 145)) ((2012 HD Sportster Parts Catalog pg 149)) ((2013 HD Sportster Parts Catalog pg 163)) ((2014 HD Sportster Parts Catalog pg 113)) ((2015 HD Sportster Parts Catalog pg 115)) ((2016 HD Sportster Parts Catalog pg 135)) \\

|Year Model|Tank Part #|Dipstick|
|1986-1993|62475-83 \\ All|62595-82A \\ All|
|1994-1996|62475-94 \\ All|62595-82A \\ All|
|1997-1998 \\ (99451-98A) \\ (99451-98)|62475-97 \\ All|62634-84A|
|1998 \\ (99451-98B)|62475-97A \\ All|62634-84A|
|1999|62475-97 \\ All|62634-84A|
|2000-2003|62888-99 \\ All (except 883R)|62634-84A|
|:::|62951-02 - 883R \\ (black)|:::|
|2004 \\ (99451-04)|62888-04 \\ All|63000-04 \\ All|
|2004 \\ (99451-04A)|62888-04B \\ All|63000-04B \\ All|
|2005|62888-04 \\ All|63000-04 \\ All|
|2006|62888-04 \\ All|63000-04A \\ All|
|2007-2008|62888-04A \\ All|63000-04A \\ All (except 1200N)|
|:::|:::|62592-07 - 1200N|
|2009|62888-04A \\ All (except XR1200)|63000-04B \\ (except 883N/1200N/XR1200)|
|:::|:::|62592-07A - 883N/1200N|
|:::|62888-08 - XR1200/XR1200X|63008-08 - XR1200|
|2010-2013 \\ (with built in 10psi relief valve) ((khaskins of the XLFORUM http://xlforum.net/forums/showthread.php?t=627620))|62954-10 \\ All (except XR1200/XR1200X)|63000-04B \\ (except 883N/1200N/XR1200/XR1200X)|
|:::|:::|62592-07A - 883N/1200N|
|:::|62888-08A - XR1200/XR1200X|63008-08 - XR1200/XR1200X|
|2014-2016|62500017 \\ All|63000-04B - except 883N|
|:::|:::|62592-07A - 883N|

====== Oil Line Routing ======

====== Oil Tanks ======
===== 1986-2003 =====

|  1997-1999 Oil Tank and cover (62475-97). (All models) ((photo by Hippysmack))  |||
|{{: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|}}|

===== 2004-Up =====
==== 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). \\
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?). \\

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. \\

|  04-09 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|}}|
==== 2010-2013 ====

In 2010 they revised the oil tank again (62954-10), AND the electrical junction block (to better protect it from moisture). \\
They also moved the ECM from under the seat to behind the rear jug. \\
A 10 psi pressure relief valve was installed in the top of the tank. ((CBAS5 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1587844&highlight=62954-10&page=3)) \\
If the vent line / vent tube is pinched or restricted, tank overfilled etc., excessive pressure is created in the oil tank. \\
The valve opens if the pressure in the tank exceeds 10 psi to prevent damage to the oil tank. \\
The oil return line was also relocated to right hand side of XL models due to the ECM relocation. \\
It could also be speculated that the return line was relocated to place it farther away from the tank vent line. \\

{{:techtalk:evo:oil:10-13-oiltank-new.jpg?direct&300|}} \\

|  2010-2013 Oil Tank (62954-10). (All models except XR1200/XR1200X) ((photos by ofaloto.tupi of the XLFORUM http://xlforum.net/forums/showthread.php?p=5759948#post5759948))  |||
|{{:techtalk:evo:oil:2010-2013_oil_tank_4_by_ofaloto.tupi.jpg?direct&300|}}|{{:techtalk:evo:oil:2010-2013_oil_tank_3_by_ofaloto.tupi.jpg?direct&300|}}|{{:techtalk:evo:oil:2010-2013_oil_tank_2_by_ofaloto.tupi.jpg?direct&300|}}|

|  2010-2013 Oil Tank Cover. ((photos by H48D of the XLFORUM http://xlforum.net/forums/showthread.php?t=1032759))  ||
|{{:techtalk:evo:oil:2010_oil_tank_cover_2_by_h48d.jpg?direct&300|}}|{{:techtalk:evo:oil:2010_oil_tank_cover_1_by_h48d.jpg?direct&300|}}|



\\


====== Oil Tank Pressure ======
See the full article, [[techtalk:ref:oil20|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. ((Deimus of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313)) \\

\\

====== Fittings ======

===== At the Oil Tank =====
Be careful of the feed line on 94-03 models as the FSM diagram is mis-leading. ((Hippysmack)) \\
Feed comes off the oil pump, under the engine, tees to the drain and up to tank. \\
The oil pump scavenger (return) is on the top of the oil pump at the front fitting.\\
On the tank, the feed is the big nipple (1/2") on the back side. ((Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?s=1805bf492596d317acbd024af1df75fa&p=5345059)) \\
The return and vent lines are on the side of the tank facing the front of the bike. \\

Oil hose sizes: ((hidollartoys of the XLFORUM http://xlforum.net/forums/showthread.php?t=947419)) \\
Feed hose: 1/2 " at tank but changes to 3/8" prior to pump. \\
Return hose: 3/8" from pump to tank. \\
Vent hose: 1/4" from cam chest fitting to tank. \\

In the pics below; \\

  * A is the drain
  * B is the feed
  * C is the vent
  * D is the return

|  1983-1993 Oil Tank Fittings  |  94-03 Oil Tank Fittings ((photo by AnaChris of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?postid=5214735))  |
|{{:techtalk:evo:oil:1983-1993_sportster_oil_tank_fittings.jpg?direct&300|}}|{{:techtalk:evo:oil:94-03_oil_tank_by_anachris.jpg?direct&300|}}|

|  2004-2009 Oil Tank Fittings ((photo by Dragonis of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=148936))  |  2010-2013 Oil Tank Fittings \\ (All except XR1200X / XR1200R) ((photo by ofaloto.tupi of the XLFORUM http://xlforum.net/forums/showthread.php?p=5759948#post5759948))  |  2014 and Up Oil Tank Fittings ((photo by Revolver944 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5373531 labeled by Hippysmack))  | 
|{{:techtalk:evo:oil:05_oil_tank_fittings_by_dragonis.jpg?direct&300|}}|{{:techtalk:evo:oil:2010-2013_oil_tank_1_by_ofaloto.tupi.jpg?direct&300|}}|{{:techtalk:evo:oil:2014_oil_tank_by_revolver944_cropped_by_hippysmack.jpg?direct&200|}}|


===== At the Oil Pump =====
Fittings are labeled in the pics below. \\

|  86-90 oil pump fittings labeled. ((photo by Hippysmack))  |  91 and Up oil pump fittings labeled ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?s=1805bf492596d317acbd024af1df75fa&p=5345059))  |
|{{:techtalk:evo:oil:86-90_oil_pump_oiling_paths_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:02_oil_pump_by_scuba10jdl.jpg?direct&300|}}|



===== At the Filter Pad =====
==== 1986-1990 ====
|  Oil filter connections. ((photo by Hippysmack))  |
|{{:techtalk:evo:oil:86-90_oil_filter_mount_2_by_hippysmack.jpg?direct&300|}}|


\\

====== Check Your Hoses for Cracks ======
Periodically inspect all your oil hose connections for leaks or cracks / deteriation, especially before long rides. \\

{{:techtalk:evo:oil:cracked_oil_hose_by_mcqueen.jpg?direct&300|}} ((photo by McQueen of the XLFORUM http://xlforum.net/forums/showthread.php?t=2069146)) \\

====== Drain Hose Locations per Year Model ======
===== 83-93 models =====
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 batter strap is fastened) ((John Harper of the XLFORUM http://xlforum.net/forums/showthread.php?t=1985862)) \\
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. \\

|{{:techtalk:evo:oil:1989_xlh_1200_engine_oil_drain_hose_by_rokkenroll.jpg?direct&300|}}|
|  Engine oil drain hose location on a 1989 XLH 1200 ((photo by RökkenRöll of the XLFORUM http://xlforum.net/forums/showthread.php?t=2069295))  |

===== 94-03 models =====
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. \\

|{{:techtalk:evo:oil:oil_return_and_drain_hose_by_matt_black.jpg?direct&300|}}|{{:techtalk:evo:oil:1998_1200s_engine_oil_drain_hose_by_hippysmack.jpg?direct&300|}}|
|  Oil feed and drain hose ((photo by Matt Black of the XLFORUM http://xlforum.net/forums/showthread.php?t=2067584))  |   Engine oil drain hose location on a 1998 1200S ((photo by Hippysmack))  |

===== 04-05 models =====
==== Sub Documents ====
  * [[techtalk:evo:oil04a|04-05 Oil Drain Plug Mods]]

----

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. \\

|{{:techtalk:evo:oil:05_drain_hose_clamp_1_by_harley506d.jpg?direct&300|}}|{{:techtalk:evo:oil:05_drain_hose_clamp_2_by_harley506d.jpg?direct&300|}}|{{:techtalk:evo:oil:04_oil_drain_clamp_by_bsaman.jpg?direct&300|}}|
|  Drain clamp on 04-05 models ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072273&page=3))  ||  Wider view ((photo by bsaman of the XLFORUM http://xlforum.net/forums/showthread.php?t=691283&page=2))  |


===== 06-Up models =====
The MoCo eliminated the clamp itself and went to a solid plastic plug (33123-06). ((sportsterpaul of the XLFORUM http://xlforum.net/forums/showthread.php?t=1232772&highlight=frame+clamp&page=46)) \\
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 ((CitySlicker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1232772&highlight=frame+clamp&page=47)) \\

|  Drain plug location on an 06 883 ((photos by southflasportster of the XLFORUM http://xlforum.net/forums/showthread.php?t=463361&page=2))  |||
|{{:techtalk:evo:oil:06_oil_drain_plug_location_1_by_southflasportster.jpg?direct&300|}}|{{:techtalk:evo:oil:06_oil_drain_plug_location_2_by_southflasportster.jpg?direct&300|}}|{{:techtalk:evo:oil:06_oil_drain_plug_location_3_by_southflasportster.jpg?direct&300|}}|

The plastic plug was updated (33123-06A).

|  09-up oil tank drain plug ((photo by harley506d of the XLFORUM http://xlforum.net/forums/showthread.php?p=5730843#post5730843))  |
|{{:techtalk:evo:oil:09-17_oil_drain_plug_by_harley506d.jpg?direct&300|}}|


===== Drain Hose Mods =====

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