I did a lot of crack repair on aluminum in my days. Mostly aluminum cylinder heads and they had to be water tight with no sealer used.
An experienced welder could repair that with TIG. Remove the sender to eliminate stress , notch the crack all the way down to the hole where the sender goes.
Fill it back up , use an NPT tap to reestablish threads ( auto transmission fluid works great as a lube)for the sender and flatten out the filter o-ring surface. Sounds easier than it is but as was said before, a good welder /machinist can do it if theres access on the bike.However, if they screw the repair up that really puts you in a bad spot. Tough call for sure..

 

Which rubber line is under feed pressure to the engine on a Sportster?

Paul

 

I'm embarrassed I missed it! Any links or pointers on the "Tee" @chopper_man ?

 

I think that's the $64,000 dollar question? I'm waiting on that one.

 

My point ( obviously missed by some ) is that there is more than likely another location that could be used to relocate the pressure switch ... Not suggesting a rubber line should be used !!

 

There is a rubber hydraulic pressure line from the pump outlet side to the filter housing. Mine has a removable fitting at the pump, to allow pump priming if necessary.

You could install the sender off the pump, it's just a flare fitting I believe. Never had to loosen it, luckily, looks a bit tough to get at. But, you could put a "T" fitting there.

John

 

Don't know where it's located, before I posted I searched for 2003 sportster 883 oil line and these showed up: https://duckduckgo.com/?q=oil+line+2...ages&ia=images

As for the T, use a 1/2 tee with 2 male barb's and a 1/2x1/8 adapter.

 

That bad boy does have an external pressure line under the right side of the motor with a fitting attached to a pressure hose going to the oil filter it appears. The lower one is the pressure I think. My guess is it could be Tee there or Tee where that hose goes. Doesn't really show where it goes on a fish. Did not realize a Sporty had an external Oil Pump hidden under the motor. Not as obvious as the EVO.
NPN, shoot some more pictures to entertain us with.

Older Sporties had the sensor there.

Keep in mind old Sporties have a spring check in line. It tends to keep a little pressure up at idle so light does not indicate low oil pressure. On this model it is in inlet of filter housing behind the thread for filter, so down stream should work for a pressure fitting.

 

The pump outlet is NPT female, with a small male-to-male adapter to a AN male flare. You may have to pull off the pump to give you clearance to thread in a "T" fitting. I'd go with NPT male (pump outlet) to AN male flare (pressure hose), with the sender outlet NPT (male or female, depends what you find for a T). I'm sure someone makes a configuration like that. Just have to be an internet sleuth. You could have the sender directly below the outlet, it looks like there is some room on my 1991, yours should be the same.

Maybe even an AN female to AN male with the NPT in the middle? There are all kinds of fittings and adapters out there, just have to find them.

John

 

I used to work in the machine tool industry, when a casting had a hairline crack, we used to repair it with Belzona, once cured Belzona can be drilled and tapped if required, just like metal.