CHROME FUEL TANK TRIM PANEL
J030752004-03-26
GENERAL
Kit Number
61653-04
Models
This kit fits all 2004 and later XL883C (Sportster® 883 Custom) and XL1200C (Sportster® 1200 Custom) model motorcycles. The Chrome panel is a direct replacement for the standard polished panel on XL1200C models.
This trim panel also fits all 2004 and later XL models equipped with a Genuine Motor Parts Large Capacity Fuel Tank.
Special Tools Needed
Console Alignment Ring, Harley-Davidson Part Number HD-47114.
Temporary use of a smaller diameter fuel filler cap (Harley-Davidson Part Number 61272-92B) on models not so equipped. This is the original equipment cap found on 2004 or later XL883 and XL1200R Sportsters, as well as many other Harley- Davidson models.
XL1200C models will need approximately 18 inches (0,46 M) of fishing line (or string) to aid in removing the existing trim panel.
NOTE
We recommend that this kit be installed by a factory trained technician at your Harley-Davidson dealership. Improper installation of this kit could result in misalignment of the trim panel and/or damage to the vehicle finish.
INSTALLATION
| 1. | Refer to the Owner's Manual and follow the instructions given to remove the seat. Retain all seat mounting hardware. | |
 WARNINGStop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) | ||
| 2. | See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. |
For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank
- To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly.
- Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10.
For Model XL1200C
| 1 | Original fuel tank trim panel liner |
| 2 | Fishing line (or string) |
Figure 1. Removing the Existing Trim Panel (XL 1200C)
| 3. | See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish | |
| 4. | Using a side-to-side "sawing" motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. | |
| 5. | Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive. NOTE To avoid damaging the tank finish, do not use tools or abrasive cleaners to remove the adhesive residue that remains on the tank surface, and try to stay within the area that will be covered by the new trim panel. NOTE Use of cleaning compounds other than isopropyl alcohol may damage tank finish. Test in inconspicuous area. | |
| WARNING Observe warnings on labels of cleaning compounds. Failure to follow warnings could result in death or serious injury. (00076a) | ||
| 6. | See Figure 2. To remove any adhesive residue remaining on the tank surface: a. Carefully peel off as much adhesive as possible, using your thumb and fingers only. b. Clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water or, if necessary, straight isopropyl alcohol. c. Allow the tank surface to dry thoroughly |  Figure 2. Removing the Adhesive Residue (XL 1200C)  Figure 3. Mark the Fuel Tank Centerline |
| 7. | Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. |
For ALL Models
| 8. | Obtain the new fuel tank trim panel. Measure and mark the centerline of the trim panel at the rear of the panel. | |
| 9. | See Figure 4. Place Console Alignment Ring HD-47114 over the fuel filler cap | |
| 10. | Peel the liner from the adhesive backing of the trim panel. | |
| 11. | Position the trim panel over the tank without touching the adhesive to the tank surface. Center the large hole over the positioning tool, and align the mark on the rear of the trim panel with the mark made on the rear of the tank. | |
| 12. | Slide the front of the trim panel down the positioning tool onto the tank. Bring the rear of the trim panel down, keeping the marks aligned. | |
| 13. | Press the trim panel firmly against the top of the fuel tank and hold pressure for 30 seconds. After releasing pressure, avoid direct contact with the panel for about 20 minutes, then remove the positioning tool. | |
| 14. | Refer to the Owner's Manual and follow the instructions given to install the seat. | |
| WARNING After 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) | ||
| 15. | Allow AT LEAST 24 hours after applying the trim panel before exposing the area to vigorous washing, strong water spray or extreme weather. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperatures. |
Figure 4. Trim Panel Positioning Tool HD-47114
SERVICE PARTS
Figure 5. Service Parts: Chrome Fuel Tank Trim Panel (Console)
Table 1. Service Parts: Chrome Fuel Tank Trim Panel (Console)
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Tank trim panel (chrome) | Not Sold Separately |
Items mentioned in text, but not included in kit. | ||
A | Original equipment fuel filler cap | |
B | Small-diameter fuel filler cap | |
C | Console Alignment Ring HD-47114 | |