0/0
XL OIL TANK KIT
J005722005-03-04
GENERAL
Kit Number
62472-93A and 62482-93A
Models
XL Oil Tank Kit 62482-93A is designed for installation on 1982 to early 1987 XLH model vehicles. XL Oil Tank Kit 62472-93A is designed for installation on late 1987 to 1993 XLH model vehicles. This kit will not fit 1983 and 1984 XR-1000 model vehicles.
Kit Contents
See Figure 9 and Table 1 for the kit contents.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
DISASSEMBLY
NOTE
A Service Manual for your motorcycle is available from your Harley-Davidson Dealer.
1. Remove exhaust system. Save all parts and hardware for reassembly.
2. 1982 Models Only. Remove forward chain guard.
3. Drain oil from tank. Follow procedure listed in appropriate Service Manual.
4. Remove seat. Retain all mounting hardware, including screw, lockwasher and plastic washer, for reassembly.
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
5. With battery disconnected (negative cable first), remove battery strap, nut and washer. Save all hardware. Remove battery from motorcycle.
6. See Figure 1. Unplug starter relay connector from starter relay on back of oil tank.
7. Loosen two bolts and one nut securing battery tray to vehicle. Remove and discard tray. Discard all hardware.
8. California and all 1992 and Later Models Only. Remove vapor valve.
9. Remove all hose clamps and disconnect feed, return and vent hoses from fittings on existing oil tank.
10. Remove three nuts and remove oil tank from motorcycle.
11. Loosen screw and remove starter relay from back of oil tank. Save relay and screw.
12. Remove screw and clamp securing rear brake line to sprocket cover. Save all hardware for reassembly.
1Relay
Figure 1. Starter Relay Location
1Rubber mounts
2Oil tank
3Hose, drain/feed, 3 in.
4Elbow (1991-93)
5Hose clamps
6Trim strips
7Tee fitting (1982-1990)
Figure 2. Oil Tank Assembly
13. Remove rear brake line mounting hardware, which includes two screws and two rubber coated clamps, one of which is located on the swing arm and one on the frame. Remove Allen fastener from brake bracket.
14. Loosen brake line fittings at rear brake master cylinder and rear brake caliper. Remove wires from rear brake switch and remove rear brake line.
15. Remove three socket head bolts securing sprocket cover to motorcycle. Remove sprocket cover.
16. Loosen nut on rear engine mount and remove negative battery cable. Discard cable. Save hardware.
17. Loosen nut at starter motor terminal (12 mm socket required) and remove positive battery cable. Discard cable. Save hardware.
18. Remove ignition module cover. Retain cover and all mounting hardware for reassembly.
19. Remove battery tray rubber mount and nut from frame tab and discard hardware.
OIL TANK SUB-ASSEMBLY
NOTE
Battery tray rubber mount from kit has two different size studs. Do not inadvertently install this rubber mount onto the oil tank as an oil tank rubber mount.
  1. See Figure 2. Install three new rubber mounts (1) from kit onto new oil tank (2).
  2. Install original starter relay on back of oil tank using original hardware.
  3. See Figure 2. Install three protective trim strips (6) on edges of oil tank (2) in locations shown in Figure 2 and Figure 3. Use a rubber mallet to tap strips into place.
    4. NOTE
    Install trim pieces to forward edge of battery tray mount bracket.
  4. Install and clamp 3-inch oil tank drain/feed hose (cut to 2-1/2 inch length on 1982-1990 models only) (3) to oil tank, in order shown. On 1991-1993 install elbow (4) also.
  5. See Figure 3. Trim the heat shield (8) to the proper length and fit over the drain/feed hose (3).
  6. 1991-93 Models Only. Sub-assemble feed and drain hose components including 8-inch drain feed hose (11), preformed 4-1/4 inch hose (13), tee fitting (7), hose clamps (5), Corbin clamp (10) and plug (9), as shown in Figure 3. Do not attach to oil tank at this time.
NOTE
See Figure 2. When installing hose (3) and elbow (4) in the following step, make sure hose assembly is properly oriented. The elbow, when in position on installed oil tank, will be directed at a 90° angle downward.
1Rubber mounts
2Oil tank
3Hose, drain/feed, 3 in.
4Elbow (1991-93)
5Hose clamps (1991-93)
6Trim strips
7Tee fitting (1982-1990)
8Heat shield
9Drain plug (1991-93)
10Corbin clamp (1991-93)
11Hose, drain/feed, 8 in. (1991-93)
12Feed line from oil pump (1991-93)
13Hose, preformed drain, 4-1/4 in. (1991-93)
Figure 3. Hose/Tee Fitting Assembly and Tank
INSTALLATION - TANK AND HOSE ASSEMBLY TO VEHICLE
NOTE
See Figure 4. Negative battery cable has an indicator mark on its terminal. To ensure proper battery cable orientation, begin installation by securing negative cable at rear engine mount terminal with indicator mark facing rearward.
1. See Figure 4. Install one piece positive/negative battery cable assembly onto motorcycle. Tighten rear engine mount to 65-80 in-lbs. Tighten starter nut to 65-80 in-lbs.
2. Install battery tray rubber mount to frame, using smaller stud. Secure with 7/16 inch nut from kit.
3. Pull return and vent hoses from left side of vehicle to right side so they are accessible for reinstallation.
4. Install oil tank assembly and secure to frame tabs with three rubber oil tank mount nuts from kit. Torque to 3-5 ft-lbs.
5. 1991-93 Models Only. See Figure 5. Route feed/drain hose sub-assembly, as shown. Clamp assembly to elbow using hose clamp (5) in kit.
6. 1991-93 Models Only. Route existing feed, return and vent lines to the fitting locations on the new tank. Trim all hose lengths as necessary. Clamp the feed line to the remaining tube on the tee fitting, as shown in Figure 3. Using hose clamps secure the return and vent hoses to the tank, as shown in Figure 7.
7. 1982-1990 Models Only. See Figure 6. Install the 4-1/4 inch preformed drain hose on tee fitting. Secure with clamp. Install drain plug and Corbin clamp.
8. 1982-1990 Models Only. Install and clamp small fitting of tee fitting to original oil pump feed hose.
9. 1982-1990 Models Only. Assemble the remaining large fitting of the tee fitting to the drain/feed hose from the oil tank. Secure with clamp from kit. Orient all hoses as shown in Figure 6.
10. Reinstall sprocket cover and torque socket head bolts to 90-110 in-lbs.
11. 1990-93 Models Only. Remove T-bushing from frame tab where brake line is to be installed. Install clip nut from kit.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a)
12. Route and install new brake line from kit. Install original retaining screw at frame tab and two screws and retaining clips on frame and caliper. Use new banjo washers on late-1987 and later vehicles. Tighten banjo bolts on late 1989-1993 vehicles (steel/rubber washers) to 17-22 ft-lbs. Tighten banjo bolts on late-1987 to early-1989 vehicles (copper/zinc washers) to 30-35 ft-lbs. Torque clip screws to 15-21 in-lbs. Torque Allen screw to 5-10 ft-lbs.
13. See Figure 8. Install new battery tray (1) using three 5/16-18 x 3/4 in. bolts (2) and 1/4-20 x 5/16 x 7/16 in. locknuts from kit. Position battery cables making sure that retaining clip (3) is installed to battery tray. Torque bolts to 12-15 ft-lbs. Torque nut 6-10 ft-lbs. Install three battery tray pads (4) from kit.
14. Install and reconnect the vapor valve and hoses.
15. 1982 Models Only. Reinstall forward chain guard using original hardware.
16. Connect starter relay plug.
1Positive cable
2Negative cable
3Drain hose
4Feed/drain hose
5Ground wire
6Battery tray bracket
Figure 4. Battery Cable Connection
1Feed hose
2Oil tank drain line
3Tee
4Drain/feed hose
5Hose clamp
6Oil drain plug
Figure 5. Sub-Assembly Routing and Connections (1991-93)
1Oil tank
2Starter motor
3Drain/feed hose
4Drain hose
5Feed hose to oil pump
6Tee fitting
Figure 6. Sub-Assembly Routing and Connections (1982-1990)
WARNING
Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a)
17. Bleed rear hydraulic system following the detailed instructions in the appropriate Service Manual.
18. Reinstall original exhaust system using original hardware.
19. Reinstall ignition module cover using three spacers, from kit, between rubber mounts and ignition cover.
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
20. See Figure 8. Install battery. Reconnect cables to battery terminals, positive cable first.
21. Fill oil tank to level recommended in appropriate Service Manual. Install cap. Check for leaks and proper oil level.
22. Install two cable straps from kit (if necessary) to replace cable straps previously removed.
23. Install seat using original hardware.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
24. See Figure 9. Secure drain hose to frame with cable strap (10).
1Oil tank
2Oil return hose
3Return hose clamp
4Gear case vent hose (1982-1990 models)
5Gear case vent hose (1991-1993 models)
6Vent hose clamp
7Feed/drain hose
Figure 7. Connecting Oil Tank Hoses
1Battery tray
2Bolt (3)
3Battery cable retaining clip
4Battery pad
5Bolt
6Battery cable
7Spacer
8Battery
Figure 8. Battery installation
Figure 9. Service Parts: Oil Tank Assembly
Table 1. Service Parts: Oil Tank Assembly
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Bolt, 5/16-18 x 3/4 in. (3)
3930A
16
Brake line assembly (Kit 62482-93A)
44438-82A
2
Screw
4092
Brake line asssembly (Kit 62472-93A)
Not Sold Separately
3
Spacer (3)
6073
17
Battery pad (2)
47403-75A
4
Washer (3)
6702
18
Oil tank assembly
62475-97A
5
Lockwasher
7041
19
Tee fitting
62493-89
6
Locknut, 1/4-20 x 5/16 x 7/16 in. (3)
7686
20
Elbow
62494-94B
7
Locknut
7739
21
Trim strip (4)
62540-83
8
Clip nut
8102
22
Rubber oil tank mounts (3)
62563-65
9
Clamp
10014
23
Battery tray mount
62569-94
10
Cable strap
10039
24
Oil drain plug
62725-90
11
Corbin clamp
10049
25
Hose, oil drain, preformed
63504-94
12
Clamp, oil hose (2)
10080
26
Hose, oil drain, 8 in.
63542-94A
13
Clip, vapor valve
10108
27
Hose, oil drain, 3 in.
63564-94A
14
Clamp, oil hose (5)
10142
28
Battery tray
66194-94A
Item 15 in Kit 62472-93A only
29
Battery cable assembly
70079-94
15
Banjo washer, copper/zinc (4)
41731-82
30
Cable strap (2) (not shown)
10006
Banjo washer, steel/rubber (4)
41731-88A
31
Heat shield
63576-95