Softail Fuel Tank and Gasket Kit

941000872019-04-19

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾	Time
61000048xxx, 61000075xxx, 61000107xxx, 61000109xxx, 61000154xxx, 61000155xxx, 61000156xxx, 61000190xxx, 61000191xxx, 61000192xxx, 61000194xxx, 61000197xxx, 61000198xxx, 61000203xxx, 61000205xxx, 61000212xxx, 61000213xxx, 61000225xxx, 61000226xxx, 61000232xxx, 61000240xxx, 61000241xxx, 61000242xxx, 61000243xxx, 61000244xxx, 61000245xxx, 61000247xxx, 61000277xxx, 61000288xxx, 61000303xxx, 61000304xxx, 61000305xxx, 61625-01xxx, 61625-07xxx, 61625-08xxx, 61625-09xxx, 61625-10xxx, 61625-11xxx, 61625-12xxx, 62177-00xxx, 62178-00xxx, 62191-03xxx, 62198-03xxx, 62206-05xxx, 62206-06xxx, 62207-05xxx, 62207-06xxx, 62207-07xxx, 62207-08xxx, 62207-09xxx, 62207-10xxx, 62207-11xxx, 62207-12xxx, 62207-13xxx, 62207-14xxx, 62208-06xxx, 62208-07xxx, 62208-08xxx, 62208-09xxx, 62208-10xxx, 62208-11xxx, 62208-13xxx, 62208-14xxx, 62210-06xxx, 62210-07xxx, 62210-08xxx, 62210-09xxx, 62211-07xxx, 62211-08xxx, 62211-10xxx, 62211-11xxx, 62240-06xxx, 62248-11xxx, 62248-13xxx, 62248-14xxx, 62292-05xxx, 62292-06xxx, 62292-07xxx, 62292-08xxx, 62292-09xxx, 62292-10xxx, 62292-11xxx, 62292-12xxx, 62292-13xxx, 62292-14xxx, 62305-06xxx, 62322-11xxx, 62322-12xxx, 62322-13xxx, 62326-07xxx, 62326-08xxx, 62326-09xxx, 62326-10xxx	Safety Glasses, Fuel Container, Hex and Torx Bit Set, Basic Socket and Wrench Set, Torque Wrench		1 hour

(1) Tightening to torque value or other moderate tools and techniques required.

KIT CONTENTS

Figure 1. Kit Contents: Softail Fuel Tank Kit

Table 2. Kit Contents: Rider Backrest Components

	Item	Qty	Description	Part No.	Notes
	1	1	Fuel tank (Typical)	Not sold separately
	2	1	Top plate gasket	61381-02A

NOTE

Verify that all contents are present in the kit before installing or removing items from vehicle.

GENERAL

Models

For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Verify that the most current version of the instruction sheet is used. It is available at: www.harley-davidson.com/isheets

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

Installation Requirements

WARNING

Rider 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)

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)

REMOVE

1.	NOTE This instruction sheet references service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer. See the service manual of the year and model vehicle that the service is being performed on for the following steps. Purge and disconnect fuel supply line.
2.	Remove main fuse.
3.	Remove fuel pump and fuel gauge sending unit.
4.	Remove fuel tank.
5.	Remove fuel supply check valve/tube.

INSTALL

NOTE

When replacing a fuel tank, use new gasket (Part No. 61381-02A) that comes in the kit with the fuel tank.

1.	From removed top plate, remove gasket and discard.
2.	Clean gasket area. a. Clean with a 50:50 isopropyl alcohol/water solution, thoroughly clean gasket surfaces. Allow to dry completely.
3.	Install new gasket under top plate. NOTE Do not apply any type of sealant to gasket.
4.	Install fuel pump and fuel gauge sending unit. See the service manual.
5.	Install top plate assembly on fuel tank.
6.	NOTE New screws are not part of the new replacement tanks. See Figure 2. Install new screws. Tighten per sequence. Torque: 2–2.7 N·m (18–24 in-lbs)

Figure 2. Top Plate Torque Sequence

7.	NOTE See the service manual of the year and model vehicle that the service is being performed on for the following steps. Install fuel supply check valve/tube.
8.	Install fuel tank.
9.	Install main fuse.

COMPLETE

1.	Fill fuel tank. Check for leaks.
2.	Clear any Diagnostic Trouble Code (DTC) that was set due to running the engine with fuel pump module connector [86] disconnected.