ROUND STYLE LOCKING FUEL CAP

941002012021-09-15

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
61100188	Safety Glasses, Torque Wrench

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

KIT CONTENTS

Figure 1. Kit Contents: Round Style Locking Fuel Cap

Table 2. Kit Contents: Round Style Locking Fuel Cap

Verify that all contents are present in the kit before installing or removing items from vehicle.
Item	Qty	Description	Part No.	Notes
1	1	Fuel tank locking filler assembly w/gasket	61000616
2	1	Lockset, unkeyed (Includes items 4-7)	Not sold separately
3	1	Clamp, hose	29379-08
4	1	Cylinder sub-assembly	Not sold separately
5	10	Tumbler spring	Not sold separately
6	24	Tumbler	Not sold separately
7	1	Grease (not shown)	Not sold separately	Kluber Lubrication: CENTOPLEX 1 DL 1 cc/1 mL/0.03 oz Observe good industrial hygiene practices Wash hands after handling Keep out of eyes Chemical Nature: Mineral oil, lithium calcium soap

GENERAL

Models

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

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

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

WARNING

Keep gasoline away from ignition sources. Gasoline is extremely flammable and highly explosive and, if ignited, could result in death or serious injury. (00634b)

Installation Requirements

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 the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.

REMOVE

1.	Figure 2 Remove tank console (1). a. Remove screws (2).
2.	Figure 3 Remove existing fuel cap. a. Cut hose clamp that secures vapor hoses to fuel cap. b. Disconnect vapor hoses (3). c. Remove screws (1). Retain.

1	Tank console
2	Screw (2)

Figure 2. Tank Console

1	Screws (6)
2	Fuel cap assembly
3	Vapor hose (2)
4	Vapor hose connection (2)

Figure 3. Fuel Cap Assembly Removal

INSTALL

Setting Key Lock

1.	Figure 4 On Original Equipment (OE) vehicle key, determine cut depth at each key station.
2.	Write values into Table 3.
3.	Table 3 Write key depth codes from Figure 4 based on cut depths measured. NOTE Cut depth codes to be second digit of tumble numbers. a. Stations 8,5,4,1: These stations use tumbler #11-14. b. Stations 7,6,3,2: These stations use tumbler #21-24.
4.	Figure 5 Install tumbler springs (5), see Figure 1 , into holes at stations 8,5,4 and 1 on side (A) of cylinder sub-assembly. NOTE Place a piece of tape or hold installed tumbler springs and tumblers with a finger to hold spring and tumblers in place before installation of springs and tumbler on opposite side of cylinder sub-assembly.
5.	Figure 5 Install tumblers (6), see Figure 1 , #11-14 in stations 8,5,4 and 1 per tumble numbers determined in Table 3.
6.	Figure 5 Install tumbler springs (5), see Figure 1 , into holes at stations 2,3,6 and 7 on side (B) of cylinder sub-assembly.
7.	Figure 5 Install tumblers (6), see Figure 1 , #21-24 in stations 2,3,6 and 7 per tumble numbers determined in Table 3.
8.	Figure 6 While holding tumblers fully in place, install key in assembled cylinder sub-assembly.
9.	Verify that all tumblers are assembled correctly. NOTE When key is fully inserted, all eight tumblers should be flush with outer diameter of cylinder. Note tumblers that are not flush. If tumbler is high on the spring side, replace with next higher number tumbler. If tumbler is high on the opposite side, replace with next lower number tumbler.
10.	Apply an even layer of grease around outer diameter of tumbler area.

Table 3. Key Lock Instructions

Station	Side	Tumbler No.
1	A	1__
2	B	2__
3	B	2__
4	A	1__
5	A	1__
6	B	2__
7	B	2__
8	A	1__

A	Tumbler Station
1	15.55 mm (.612 in)
2	14.45 mm (.569 in)
3	12.35 mm (.486 in)
4	11.25 mm (.443 in)
5	9.15 mm (.360 in)
6	8.05 mm (.317 in)
7	5.95 mm (.234 in)
8	4.85 mm (.191 in)
B	Cut Depths
	0.15 mm (.006 in) = Depth code 1
	0.75 mm (.030 in) = Depth code 2
	1.45 mm (.057 in) = Depth code 3
	2.25 mm (.089 in) = Depth code 4

Figure 4. Key Code Diagram

Figure 5. Spring and Tumbler Install Locations

1	Cylinder sub-assembly
2	Tumblers, installed and flush
3	Key

Figure 6. Assembled Lockset

Install Locking Fuel Cap

1.	Figure 7 If cap is latched before lock cylinder is installed, use screwdriver or other tool to press slider inside cap's lock hole while pulling cap up.
2.	Figure 8 Use screwdriver or other tool, press in locking tab (1) fully in order to properly seat lock cylinder.
3.	Figure 9 Orientate lock cylinder notch (1).
4.	Push cylinder fully into fuel cap.
5.	Release locking tab.
6.	While continuing to push cylinder in, turn key back and forth slightly until locking tab fully extends and cylinder is latched. NOTE When turning key actuates the locking tab, it is acceptable to close cap and remove key.
7.	Figure 10 Install round locking fuel cap assembly (2) with OE screws (1).
8.	Figure 10 Torque screw in sequence. Tighten. Torque: 2.8–3.3 N·m (25–29 in-lbs)
9.	Figure 1 Install hose clamp (3) on vapor hose where OE clamp was removed earlier.
10.	Figure 3 Connect vapor hoses (3).
11.	Install tank console. a. Insert tab into slot at rear of fuel tank. b. Secure with OE screws. Tighten. Torque: 3–4 N·m (27–35 in-lbs)

Figure 7. Cap Latch Slider

Figure 8. Locking Tab

Figure 9. Lock Cylinder Orientation

Figure 10. Round Locking Fuel Cap Installed / Torque Sequence