VACUUM OPERATED FUEL SUPPLY VALVE KIT
J026342020-09-22
GENERAL
This kit fits all 1995 through 2001 XL model motorcycles.
This kit contains the following items:
Table 1. Kit Contents
Qty | Description | Part No. |
|---|---|---|
1 | Valve, fuel | 62169-02 |
1 | Gasket, fuel valve | 62172-02 |
1 | Fitting, fuel valve | 62161-02 |
1 | Filter, fuel valve | 62166-02 |
NOTE
To prevent the possibility of fuel leakage, the hose clamp MUST be discarded and replaced each time it is removed.
A replacement clamp, part number 10014 and HOSE CLAMP PLIERS (Part Number HD-97087-65B) are available separately from your Harley-Davidson Dealer.
WARNINGRider and passenger safety depend upon the correct installation of this kit.
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. (00308b)
NOTE
A service manual for your model motorcycle is available from your Harley-Davidson dealer.
INSTALLATION: REMOVING THE OLD FUEL SUPPLY VALVE
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
WARNINGDisconnect 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)
| 1. | Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. |
WARNINGStop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)
| 2. | Turn the fuel supply valve handle to the “OFF” position. | |
| 3. | See Figure 1. Remove the fuel hose (6) from the fuel outlet nipple on the valve. Discard the hose clamp (5). | |
| 4. | Remove the vacuum hose (7) from the nipple on the valve. | |
| 5. | Attach a length of fuel hose onto the fuel outlet nipple and route the hose into a clean, approved gasoline container. | |
| 6. | Turn the fuel supply valve handle to the “RES” position. | |
| 7. | Using the appropriate hose adapter, connect a PLASTIC MITY-VAC® HAND PUMP (Part Number HD- 23738-A) to the vacuum nipple on the valve. | |
| 8. | Gently apply a vacuum of 1 to 10 inches of Mercury (Hg), or just enough to get a good flow of gasoline draining into the container. |
WARNINGWith fuel tank drained, gasoline can spill from bore when supply valve is loosened or removed. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00277a)
| 9. | After the tank has completely drained, turn the fitting (3) that attaches the valve to the fuel tank counterclockwise to remove the valve (1), gasket (2) and filter (4). Discard these items. |
| 1 | Fuel valve |
| 2 | Gasket |
| 3 | Fitting |
| 4 | Filter |
| 5 | Hose clamp |
| 6 | Fuel hose |
| 7 | Vacuum hose |
Figure 1. Fuel Supply Valve
INSTALLING THE NEW FUEL SUPPLY VALVE
| 1. | Coat the threads on the new fuel supply valve with LOCTITE PIPE SEALANT WITH TEFLON or equivalent. | |
| 2. | Place the new gasket from the kit onto the valve mounting surface, and install the new fuel filter onto the valve. |
WARNINGDo not thread hex nut onto valve more than two turns to prevent "bottoming" nut on valve, which can cause a fuel leak. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00276a)
| 3. | See Figure 2. Attach the fuel supply valve to the tank in this sequence. a. Thread the new fuel valve fiting (3) from the kit onto the right-hand threads of the fuel tank adapter for two turns. b. Hold the fuel valve fitting, and thread the new fuel supply valve into the left-hand threads of the fitting for two turns. c. Hold the valve and tighten the fuel valve fitting clockwise to 20.3–27.1 N·m (15–20 ft-lbs). | |
| 4. | Using a new hose clamp and HOSE CLAMP PLIERS (Part Number HD-97087-65B), connect the fuel hose to the the fuel outlet nipple on the valve. |
NOTICE
Do not allow contaminants to get into vacuum line connecting fuel valve to carburetor. Contaminants in the line could cause fuel valve to remain open. (00368a)
NOTE
If the vacuum line is connected to the atmosphere vent nipple (at the bottom of the valve) the valve will not open.
| 5. | Connect the vacuum hose to the vacuum nipple on the valve. |
WARNINGDo not allow open flame or sparks near propane. Propane is extremely flammable, which could cause death or serious injury. (00521b)
| 6. | Fill the fuel tank with gasoline, and check to ensure that there are no fuel leaks or seepage. |
WARNINGConnect 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)
| 7. | Connect the battery cables, positive cable first. |
WARNINGAfter 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)
| 8. | Refer to the service manual, and follow instructions to install the seat. | |
| 9. | Turn the fuel supply valve handle to the “ON” position and start the engine. Check for fuel leaks. NOTE No special procedures are required to start fuel flow. |
| 1 | Right-hand threads on fuel tank adapter |
| 2 | Thread fitting TWO turns |
| 3 | Left-hand threads on fuel supply valve |
| 4 | Hole fitting, rotate valve TWO turns |
| 5 | Hold valve, tighten fitting |
Figure 2. Attaching the Fuel Supply Valve to the Tank