OVAL STYLE LOCKING FUEL CAP
941002852021-09-15
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
61100187 | Safety Glasses, Torque Wrench |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Oval 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 | 61000630 | |
| 2 | 1 | Lockset, unkeyed (Includes items 4-6, 8) | 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 | 3 | Cable strap | 10006 | |
| 8 | 1 | Grease (not shown) | Not sold separately | Kluber Lubrication:
|
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.
WARNINGKeep 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
WARNINGRider 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. Cut cable straps that secures connector (5) to vent lines. c. Disconnect connector (5) from vehicle harness. d. Disconnect vapor hoses (3). e. Remove screws (1). Retain. |
| 1 | Tank console |
| 2 | Screw (3) |
Figure 2. Tank Console
| 1 | Screws (6) |
| 2 | Fuel cap assembly |
| 3 | Vapor hose (2) |
| 4 | Vapor hose connection (2) |
| 5 | Connector |
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. |
| 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 3 Install oval 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. | Figure 3 Connect connector (5) to vehicle harness. a. Secure to vent lines with cable straps. | |
| 12. | Figure 2 Install tank console. a. 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. Oval Locking Fuel Cap Installed / Torque Sequence
Table 3. Key Lock Instructions
Station | Side | Measured Depth | Depth Code | 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__ |