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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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dipstick tabs, oil bag, oil dipstick

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  #1  
Old 3rd August 2021
krono's Avatar
krono krono is offline
Senior Chief Harley Engineer
 
Join Date: Feb 2008
Posts: 1,016
Sportster/Buell Model: XL 883
Sportster/Buell Year: 2004
Sportster/Buell Model #2: XL 1200 C
Sportster/Buell Year #2: 2008
Other Motorcycle Model: XL 883 L
Other Motorcycle Year: 2005
Reputation: 379488
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Thumbs down Oil dipstick stuck

So I got a very molested XL 883 L 2005 last month, for scrap price. I'm trying to make it run again, shoestring budget...



I did a oil change today and I found the oil dipstick is destroyed, someone pried it with a screwdriver or something.The bevel on the oil tank is also all marked... so somehow this people managed to damage that too


So, I purchased a brand new temperature gauge ($80) and put it in... all right,entered good, but when I'm trying to remove it, gets stuck half turn out... after like half hour of trying to open it again, I almost had to resort to channel lock pliers but I dont want to damage my very expensive ($80) oil dipstick (shipping anything outside USA is expensive, a $30 thing in USA ends up being $100 here or more )


So... inspecting the oil hole, seems the tabs inside the tank are somehow misaligned or damaged or something...


what can I do to make this right? I tried to put and remove the oil dipstick and is very difficult, gets stuck going in and out now... about half turn, it gets ultra stuck, like both hands cursing on it and really making force to turn it... also wiggles but doesnt budge


Should I file the small tab inside the tank, leaving only the large one as a guide?
or would that make it worse?

I can't replace the whole tank, I don't have the money, nor could I get it here ...

How can I solve this without throwing more money at the problem?

the problem is not the oil cap, it is new, it works perfect, and the old one is also quite good.

I tested with three plugs, it is my third sportster, and the first time something like this has happened to me.

hole tabs are damaged or misaligned in any way

All of this was done with an automatic translator, it may not make much sense ...


__________________
XL 883 2004, XL 883 L 2005, XL 1200 C 2008, Daelim Liberty 50cc, Mondial VD 250 P
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  #2  
Old 3rd August 2021
1Scooter 1Scooter is offline
Harley Engineer
 
Join Date: Jun 2016
Posts: 327
Sportster/Buell Model: XLH1000
Sportster/Buell Year: 1977
Sportster/Buell Model #2: 2004 XLH1200Custom
Other Motorcycle Model: 2007 FXDB
Other Motorcycle Year: 2004
Reputation: 58648
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Replace the oil tank.
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  #3  
Old 6th August 2021
krono's Avatar
krono krono is offline
Senior Chief Harley Engineer
 
Join Date: Feb 2008
Posts: 1,016
Sportster/Buell Model: XL 883
Sportster/Buell Year: 2004
Sportster/Buell Model #2: XL 1200 C
Sportster/Buell Year #2: 2008
Other Motorcycle Model: XL 883 L
Other Motorcycle Year: 2005
Reputation: 379488
krono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond reputekrono has a reputation beyond repute
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To give closure to this issue, yesterday I managed to repair it!!

Going to tell how:

1. first, check with your fingers and visually the oil tabs, they are probably bent or jagged or both

2. with a small screw driver, try to straighten the tabs

3. cover the oil hole with something, like a big sheet of aluminium foil, and file the tabs a little with 180 or 240 sand paper, very little, dont go crazy, smooth the surface and round hard edges

4. examine the grooves on your oil dipstick, if they are deformed try to sand them back into the good shape, even fill with epoxy if needed

5. go testing and see how it improves, dont go overboard with the sand

6. remove the aluminium foil, was to prevent particles falling into your oil while you file/sand the rough tabs


so well, thats how I solved it, 0$, without changing the oil bag or wasting brand new oil

now my oil dipstick goes in and out smooth
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