CONSOLE, FUEL DOOR, FUEL DOOR RELEASE KITS
J059732016-08-22
GENERAL
Kit Number
70900463, 70900465, 70900501, 90300096
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Loctite® 243 Medium Strength Threadlocker and Sealant - Blue (Part No. 99642-97) to install fuel door hinge.
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)
Kit Contents
See Figure 2 and Table 1.
REMOVAL
1.
See the service manual to remove the seat. Retain the seat and all mounting hardware.
2.
See Figure 2. Open the fuel door (12). Remove and retain fuel filler cap (A).
3.
Remove and discard screw (3). Remove and retain screw (G).
4.
Carefully remove currently installed console (1) or (2).
5.
Note location and orientation of fuel pump connector (C). Unplug connector from block if necessary.
6.
Remove drain tube (D) from drain nipple (B).
7.
Note tube and harness that are under clips (9).
8.
Models with front headset connector: See Figure 1. Open headset cover (1). Place pin punch (2) in either notch (3) of lock ring (4). Rotate counterclockwise to loosen.
9.
Remove lock ring (4) and cap (see Figure 2 , Item F).
1Headset cover (weather cap)
2Pin punch
3Notch (2)
4Lock ring
Figure 1. Remove/Install Headset Connector Lock Ring
10.
All models: See Figure 2. Remove screws (8) and bracket (H). Retain bracket. Discard screws.
11.
If reusing fuel door and latch/lock: Remove and retain screws (10), clip (11) and fuel door (12).
CONSOLE INSTALLATION
1.
See Figure 2. Clean the area on the console (1 or 2) where console insert (6 or K) is applied.
2.
Remove the paper adhesive liner. Align console insert. Set the console insert in place.
3.
Apply firm pressure to the console insert at all contact points to verify a good bond.
4.
Models with front headset connector: Insert the headset connector (E) through the insert (6).
5.
Slide weather cap over headset connector (F).
6.
See Figure 1. With the notches (3) on the outboard side, thread lock ring (4) onto the headset connector.
7.
Place pin punch (2) over either notch. Rotate clockwise until tight.
8.
All models: See Figure 2. Install bracket (H). Secure with new screws (8).
9.
Install rubber molding (15) to console (1 or 2). The longer edge of each rubber molding goes on the inboard side.
10.
Install boot (5) so the smooth side is facing up.
11.
Install bumpers (4) into console as shown.
12.
Route the drain tube (D) and wires (C or E) under console. Install clips (9) to secure.
WARNING
Do not kink or pinch the fuel overflow line when installing console. A blocked line can cause an overfilled tank to leak. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00264a)
13.
Install drain tube (D) onto drain nipple (B).
NOTE
When performing this installation, do not scratch nearby painted or chrome surfaces.
14.
Center trim cover (I). Install console using care to keep boot in place around fill tube. Secure console with screw (G), removed earlier and new screw (3). Tighten screw (G) to 4.1–6.8 N·m (36–60 in-lbs) Tighten screw (3) to 2.3–3.4 N·m (20–30 in-lbs).
FUEL DOOR INSTALLATION
NOTE
Prior to installation of new fuel door, install new self-tapping screws (10) to form threads. Remove screws.
1.
Apply LOCTITE 243 (blue) to the threads of screws (10).
2.
Place hinge (11) over pin (J).
3.
Secure fuel door (12) to hinge with screws (10). Tighten the screws to 2.8–3.4 N·m (25–30 in-lbs).
LOCK REPLACEMENT
1.
Remove nut (13) and lock (14).
2.
Insert lock securing with nut. Tighten nut to 3.4–4.5 N·m (30–40 in-lbs).
3.
If installing NEW Console Door Pushbutton Release (Part No. 53842-00C): Install pushbutton assembly using new nut from Pushbutton Kit. Tighten nut to 3.4–4.5 N·m (30–40 in-lbs).
4.
See service manual. Install seat. After installing seat, pull up on the seat to verify it is secure.
NOTE
To keep the pushbutton lock assembly operating smoothly, lightly spray lubricant on the mechanism as needed.
SERVICE PARTS
Figure 2. Service Parts: Console, Fuel Door, Fuel Door Release Kits
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
70900463
Console
(Gloss Black,
WITHOUT CB
Communications
Port)
1
Console, solid center (black)
Not sold separately
3
Screw, socket head, #10-24 x 1/2 in (25 mm) long
4856
4
Bumper, cover (2)
61313-88
5
Boot
61112-08
8
Screw, self tapping (2)
4194
9
Clip, adhesive (2)
10103
15
Rubber molding (2)
71294-08
70900501
Console
(Gloss Black,
WITH CB
Communications
Port)
2
Console, open center (black)
Not sold separately
3
Screw, socket head, #10-24 x 1/2 in (25 mm) long
4856
4
Bumper, cover (2)
61313-88
5
Boot
61112-08
6
Console insert, CB Communications Port
15341-08
7
Console insert
14100083
8
Screw, self tapping (2)
4194
9
Clip, adhesive (2)
10103
15
Rubber molding (2)
71294-08
70900465A
Fuel Tank Console
Door (Gloss Black)
10
Screw, self tapping (2)
3529
12
Door, console (black)
Not sold separately
90300096
Smooth Pushbutton
Fuel Tank Console
Door Release
(Gloss Black)
11
Clip, hinge mounting
Not sold separately
13
Nut, hex
84850-92
14
Push button lock, fuel door (black)
Not sold separately
Items mentioned in text, but not included in kit:
A
Fuel filler cap
B
Drain nipple
C
Socket housing
D
Drain tube
E
CB/Communications connector
F
Weather cap assembly
G
Screw
H
Bracket, console mount
I
Trim cover
J
Pin, fuel door hinge
K
Console insert. See P&A retail catalog or www.harley-davidson.com/Parts and Accessories (English only)