• 1982-1993 Sportster Retrofit Oil Tank Kit (except XR-1000)
• Pics and Information on 1982-1993 Sportster Oil Tanks
• Pics and Information on 1994-2003 Sportster Oil Tanks
• Pics and Information on 2004-2009 Sportster Oil Tanks
• Pics and Information on 2010-2013 Sportster Oil Tanks
• Pics and Information on 2014-Up Sportster Oil Tanks

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)}

• 1986-1990 (all models):
  • Oil feed from the tank runs to the lower rear fitting of the oil pump (3/8“ hose).
  • Oil feed from the pump to the filter runs from the lower front (smaller) AN fitting to the outside threaded hole at the filter pad.
  • Oil feed from the filter to the pump is from the center hole at the filter pad to the upper (larger) AN fitting on the pump.
  • Oil return to the tank is on the upper front of the oil pump (3/8” hose fitting, 2 fittings together ending in hose barb).
  • Vent line from the oil tank is on the rear of the cam cover (1/4“ hose 90° fitting).
  • The primary / transmission is vented to atmosphere from the top of the transmission near the rear motor mount just in front of the solenoid (1/4” hose fitting).
    • The hose should run straight up and then loop back down (without kinks).
• 1991-1993:
  • Oil feed from the tank runs to the lower rear fitting of the oil pump (3/8“ hose).
  • Oil feed from the pump to the filter runs from the lower front AN fitting on the pump to the (cam side) threaded hole at the filter pad.
    (from there, oil is routed into the engine internally)
  • Oil return to the tank is on the upper front of the oil pump (3/8” hose fitting).
  • Vent line from the oil tank is on the rear of the cam cover (1/4“ hose 90° fitting).
  • The primary / transmission is vented to atmosphere from the top of the transmission near the rear motor mount (3/8” hose straight fitting).
• 1994-2003:
  • Oil feed hose from the tank doubles as a drain to a point.
    A short hose runs across the bike from the tank to a plastic 90° fitting.
    The hose turns down on the left side of the bike to just above the bottom of the left frame tube and ends into a plastic tee.
    A short hose runs from the tee around the outside of the rear tube to a steel plug welded on a bracket to the rear of the right frame tube.
    Then a longer hose runs from the tee to the lower rear fitting of the oil pump (3/8“ hose).
  • Oil feed from the pump to the filter runs from the lower front AN fitting on the pump to the (cam side) threaded hole at the filter pad.
    (from there, oil is routed into the engine internally)
  • Oil return to the tank is on the upper front of the oil pump (3/8” hose fitting).
  • Vent line from the oil tank is on the rear of the cam cover (1/4“ hose 90° fitting).
  • Primary / transmission vent:
    • 1994-1999: The primary / trans is vented to atmosphere from the top of the transmission near the rear motor mount (vertical 3/8” hose straight fitting).
    • 2000-2003: The primary / trans is vented to atmosphere from a nipple fitting on top of the primary near the starter (horizontal 3/8“ hose straight fitting).

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Simplified Oil Line Routing Drawings: ³⁴⁾
Click on a drawing to enlarge:

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. ³⁵⁾

Be careful of the feed line on 94-03 models as the FSM diagram is mis-leading. ³⁶⁾
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. ³⁷⁾
The return and vent lines are on the side of the tank facing the front of the bike.

Oil hose sizes: ³⁸⁾
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 39)

2004-2009 Oil Tank Fittings 40)	2010-2013 Oil Tank Fittings (All except XR1200X / XR1200R) 41)	2014 and Up Oil Tank Fittings 42)

Fittings are labeled in the pics below.

86-90 oil pump fittings labeled. 43)	91 and Up oil pump fittings labeled 44)

Periodically inspect all your oil hose connections for leaks or cracks / deteriation, especially before long rides.

⁴⁶⁾

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) ⁴⁷⁾
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.

Engine oil drain hose location on a 1989 XLH 1200 48)

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.

Oil feed and drain hose 49)	Engine oil drain hose location on a 1998 1200S 50)

• 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.

Drain clamp on 04-05 models 51)		Wider view 52)

The MoCo eliminated the clamp itself and went to a solid plastic plug (33123-06). ⁵³⁾
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 ⁵⁴⁾

Drain plug location on an 06 883 55)

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

09-up oil tank drain plug 56)