VACUUM OPERATED FUEL SUPPLY VALVE KIT
J026452020-09-20
GENERAL
Kit Number
61338-95C, 63338-95D
Models
This kit is designed for installation on 1994-2001 FL® (Touring), 1995-2001 Dyna®, 1995-2001 FXST® and 1999- 2000 FXR2®, FXR3® and FXR4® models.
Installation Requirements
Table 1. Kit Number 61338-95C
Qty | Description | Part Number |
|---|---|---|
1 | Fuel supply valve, vacuum operated | 61338-02 |
Table 2. Kit Number 63338-95D
Qty | Description | Part Number |
|---|---|---|
1 | Nut, fuel supply valve | 62161-02 |
1 | Gasket, fuel supply valve | 62172-02 |
1 | Filter, fuel supply valve (long screen) (FL and Dyna models) | 62170-02 |
1 | Filter, fuel supply valve (short screen) (Softail models) | 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 hose 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: REMOVE 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)
| 1. | Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative battery cable. |
WARNINGWhen servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
| 2. | See Figure 1. Turn the fuel supply valve petcock (8) to the “OFF” position. | |
| 3. | Remove the fuel hose (6) from the fuel outlet nipple on the fuel supply valve. Discard the hose clamp (5). | |
| 4. | Remove the vacuum hose (7) from the nipple on the fuel supply 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 petcock (8) 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 fuel supply 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 supply valve to the fuel tank counterclockwise to remove the fuel supply valve (1), gasket (2) and filter (4). Discard these items. |
| 1 | Fuel supply valve |
| 2 | Gasket, fuel valve |
| 3 | Nut, fuel valve |
| 4 | Filter, fuel valve (long filter shown) |
| 5 | Hose clamp |
| 6 | Fuel hose |
| 7 | Vacuum hose |
| 8 | Fuel valve petcock |
Figure 1. Fuel Supply Valve (Old)
INSTALL THE NEW FUEL SUPPLY VALVE
| 1. | See Figure 3. Coat the threads on the new fuel supply valve (1) with LOCTITE PIPE SEALANT WITH TEFLON or equivalent. | |
| 2. | Place the new gasket (2) from the kit onto the valve mounting surface, and install the new fuel filter (4) onto the fuel supply valve. |
NOTE
For FL and Dyna Models, use Fuel Filter, long screen (Part Number 62170-02). For Softail models, use Fuel Filter short screen (Part Number 62166-02). Both are provided in this kit.
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 and Figure 3. Attach the fuel supply valve (1) to the fuel tank using this sequence. a. Thread the new fuel supply valve nut (3) from the kit onto the right-hand threads of the fuel tank adapter for two turns. b. Hold the fuel supply valve nut, and thread the new fuel supply valve into the left-hand threads of the nut for two turns. c. Hold the fuel supply valve and tighten the fuel valve nut clockwise. Torque: 20.3–27.1 N·m (15–20 ft-lbs) |
| 4. | Using a new hose clamp (5) and HOSE CLAMP PLIERS (Part Number HD-97087-65B), connect the fuel hose (6) to the the fuel outlet nipple on the fuel supply 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 (7) to the vacuum nipple on the upper portion of fuel supply valve. | |
| 6. | Fill the fuel tank with gasoline, and check to ensure that there are no fuel leaks or seepage. | |
| 7. | Connect the negative battery cable. |
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 petcock (8) to the “ON” position and start the engine. Check for fuel leaks. NOTE No special procedures are required to start fuel flow. |
| 1 | Fuel supply valve |
| 2 | Gasket, fuel valve |
| 3 | Nut, fuel valve |
| 4 | Filter, fuel valve (long filter shown) |
| 5 | Hose clamp |
| 6 | Fuel hose |
| 7 | Vacuum hose |
| 8 | Fuel supply petcock |
| 9 | Threads |
Figure 2. Fuel Supply Valve (New)
| 1 | Right-hand threads on fuel tank adapter |
| 2 | Thread fuel supply valve nut TWO turns. |
| 3 | Left-hand threads on fuel supply valve |
| 4 | Hold fuel supply valve nut, rotate fuel supply valve TWO turns |
| 5 | Hold fuel supply valve, tighten fuel supply valve nut |
Figure 3. Attaching the New Fuel Supply Valve to the Tank