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DEFINITIVE5™ FILTRATION SYSTEM KITS
J039522006-07-27
GENERAL
Kit Number
63800-07, 63801-07, and 63802-07
Models
Table 1. Kits and Model/Fitments
Kits
Model and Fitments
63800-07 - Silver Powder Coat Kit
Touring: 1999-2007 Twin Cam, 1999-2006 Twin Cam with Oil Cooler 62895-03A, 1992-1998 Evolution
Dyna: 1999-2007 Twin Cam, 1991-1998 Evolution
Softail: 1992-2007 Twin Cam, 1992-1999 Evolution
FXR: 1992-1994 Evolution, 1999-2000 Evolution
Sportster: 1992-2007 Evolution
63801-07 - Black Wrinkle Power Coat Kit
Touring: 1999-2007 Twin Cam, 1999-2006 Twin Cam with Oil Cooler 62895-03A, 1992-1998 Evolution
Dyna: 1999-2007 Twin Cam, 1991-1998 Evolution
Softail: 1992-2007 Twin Cam, 1992-1999 Evolution
FXR: 1992-1994 Evolution, 1999-2000 Evolution
Sportster: 1992-2007 Evolution
63802-07 - Chrome Plated Kit
Touring: 1999-2007 Twin Cam, 1999-2006 Twin Cam with Oil Cooler 62895-03A, 1992-1998 Evolution
Dyna: 1999-2007 Twin Cam, 1991-1998 Evolution, Softail: 1992-2007 Twin Cam, 1992-1999 Evolution
FXR: 1992-1994 Evolution, 1999-2000 Evolution
Sportster: 1992-2007 Evolution
NOTE
These kits do not fit the Models with Premium Oil Cooler Kits listed in Table 2. These kits will also not fit Touring models with sidecars, and some models with front spoilers.
Additional Parts Required
Oil Filter Wrench (94686-00) is required to remove existing spin-on oil filter and can be purchased separately from a Harley-Davidson dealer.
Table 2. Will Not Fit These Models With Premium Oil Cooler Kits
Models
Oil Cooler Kits
1999-2006 Touring
2007 Touring
26082-05A
26155-07
2000-2006 Softail
2000-Later Softail
26136-05
26157-07
1999-2005 Dyna
2006 Dyna
2006-Later Dyna
26081-05A
26110-05
26151-07
1982-Later XL
62996-04
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)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 5 and Table 4.
INSTALLATION
Remove Existing Engine Oil Filter and Adapter
  1. Operate motorcycle until engine is warmed up to normal operating temperature.
  2. Place suitable container under engine to drain oil.
  3. Drain engine oil following the instructions in the Service Manual for your model.
  4. See Figure 1 and Figure 2. Remove existing spin-on oil filter using the Oil Filter Wrench. Refer to the instructions in the Service Manual for your model.
    5. NOTE
    The use of oil filter wrench can prevent damage to crankshaft position sensor and/or sensor cable.
  5. Remove oil filter adapter from oil filter housing.
Figure 1. Spin-On Oil Filter (Sportster Evolution Engine)
Figure 2. Spin-On Oil Filter (Twin Cam Engine)
Install New Engine Oil Filter
  1. See Figure 5. Lubricate anti-backflow valve (1) from kit with clean oil, then place in groove on threaded adapter assembly (2).
  2. Check if anti-backflow valve (1) is seated properly in groove of threaded adapter assembly (2).
    1. Rotate the anti-backflow valve around the threaded adapter assembly. The anti-backflow valve should spin freely.
    2. After installed, check that the outer lip of the anti-backflow valve contacts the inner base of the oil filter housing (4).
  3. Lubricate O-ring (3) with clean engine oil, then place O-ring in groove of oil filter housing (4).
  4. Select appropriate anti-rotation device (6) for your model motorcycle.
  5. Place anti-rotation device (6) into oil filter base. See Figure 4 and Table 3 for proper orientation.
1. Apply Loctite (12) to bond threaded adapter assembly (2) to oil filter mounting housing (4).
2. Place threaded adapter (2) inside oil filter housing (4).
3. See Figure 3. Align slotted hole on bottom of oil filter housing ( Figure 5 , Item 4) with tab on anti-rotation device ( Figure 5 , Item 6).
NOTE
See Figure 5 for Steps 9 through 13.
4. See Figure 5. Use 3/8 in. socket wrench extension (at least 7 in. long) to engage the square hole at bottom of threaded adapter assembly (2). Thread oil filter housing (4) into oil filter base. Tighten to 30 ft-lbs (40.7 Nm).
Figure 3. Oil Filter Housing/Anti-Rotation Device Alignment
5. Lubricate O-ring (7) with clean engine oil, then place O-ring on cover (8).
6. Install filter element (9) onto threaded adapter assembly (2).
7. Thread cover into oil filter housing (4) until hand tight.
8. Using cover wrench (11), continue to tighten cover until it is flush with oil filter housing (4).
NOTE
On 2007 and later models equipped with Oxygen sensors, the sensor harness is routed along the back side of the left frame tube. When installing this kit, it is important that the harness does not contact the oil filter housing or oil filter cover. The harness should be routed along the inside frame tube rather than the back side of the frame tube. This will ensure there is enough play in the the harness to allow for engine movement.
Reroute any electrical wires or hoses that may contact the oil filter housing during engine operation.
Figure 4. Anti-Rotation Device Orientation
Table 3. Anti-Rotation Device Orientation
Item
Letter
Model and Fitment
1
"A"
1999-2005 Dyna
1999-2006 Touring
2
"B"
2000-2007 Softail
3
"B"
2006-2007 Dyna
2007 Touring
4
"C"
1999-2006 Touring with Oil Cooler 62895-03A
5
"D"
1992-2007 Sportster
6
"E"
1991-1998 Dyna
1992-1994, 1999-2000 Evolution FXR
1992-1999 Softail
1992-1998 Touring
Add Oil and Check Engine
  1. Add engine oil following the instructions in the Service Manual for your model.
  2. Check engine oil level using cold check procedure.
  3. Start engine and carefully check for oil leaks. If necessary repair leaks before completing the installation.
  4. Check engine oil level using hot check procedure.
  5. If necessary, add oil until it registers at upper groove on dipstick. Be careful not to overfill.
Change Oil
Refer to the Service Manual for procedures to change the oil for your model motorcycle.
REPLACEMENT
Remove Oil Filter Element
  1. See Figure 5. Using the Definitive5™ cover wrench (11), loosen cover (8) and rotate until drain slots are fully visible and aligned vertically to allow draining fluid into a pan.
  2. Unscrew cover and dispose of the filter element (9) according to local regulations.
  3. Inspect interior of oil filter housing (4) for any solid matter and wipe clean with a lint free cloth.
Install Oil Filter Element
  1. See Figure 5. Install open end of filter element (9) onto threaded adapter assembly (2) and push gently over O-ring (10) to seat element.
  2. Thread cover (8) into oil filter housing (4) until hand tight. Using cover wrench (11), continue to tighten cover until it is flush with the oil filter housing.
  3. After filling oil filter tank, run engine and check for any leaks around oil drain plug and oil filter. Recheck oil level.
Threaded Adapter Assembly and Oil Filter Housing
If the threaded adapter assembly or oil filter housing require servicing, consult a Harley-Davidson dealer for assistance.
Seal Replacement Kit
The engine oil filter seals, O-rings, and pin can be replaced by ordering Seal Replacement Kit 63833-07 ( Figure 5 , Item 13). Consult a Harley-Davidson dealer for assistance.
SERVICE PARTS
Figure 5. Service Parts: Definitive5 Filtration System Kits
Table 4. Service Parts: Definitive5 Filtration System Kits
Item
Description (Quantity)
Part Number
1
Anti-backflow valve
63820-07
2
Threaded adapter assembly
Not Sold Separately
3
O-ring
11583
4
Oil filter housing (includes Item 5)
Not Sold Separately
5
Pin
Not Sold Separately
6
Anti-rotation devices (See Table 5)
Not Sold Separately
7
O-ring
11584
8
Cover, silver powder coat
63841-07
Cover, black wrinkle powder coat
63845-07
Cover, chrome plated
63847-07
9
Filter element
63834-07
10
O-ring
11585
11
Cover wrench (not shown, purchased separately)
63832-07
12
Loctite, 0.5 ml tube (Not Shown)
Not Sold Separately
13
Seal Replacement Kit (Not Shown) (includes Items 1, 3, 5, 7, 10)
63833-07
Table 5. Anti-Rotation Devices
Letter Designation
Model and Fitment
"A"
Dyna: 1999-2005 Twin Cam
Touring: 1999-2006 Twin Cam
"B"
Dyna: 2006-2007 Twin Cam
Softail: 2000-2007 Twin Cam
Touring: 2007 Twin Cam
"C"
Touring: 1999-2006 Twin Cam with Oil Cooler 62895-03A
"D"
Sportster: 1992-2007 Evolution
"E"
Dyna: 1991-1998 Evolution
FXR: 1992-1994 Evolution, 1999-2000 Evolution
Softail: 1992-1999 Evolution
Touring: 1992-1998 Evolution