FLUSH MOUNT FUEL CAP KIT
J051922022-08-08
GENERAL
Kit Number
63133-10B, 63134-10B, 63139-10B, 63140-10B, 61100006B, 61100007B, 61100133, 61100134, 61100136, 61100210, 61100211
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
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 your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
INSTALLATION
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)
NOTE
Extended exposure of gas cap to a wet environment (rain/washing) may cause a small amount of water to collect between the pop-up housing and the threaded body. Simply remove the gas cap and tilt to drain. Water cannot flow through the gas cap.
| 1. | Remove Original Equipment (OE) gas cap from fuel tank. | |||||
| 2. | Clean and wipe inside surface of fuel tank filler cup, O-ring seal surface, and trim ring adhesive surface with a mixture of equal parts of isopropyl alcohol and distilled water. | |||||
| 3. | See Figure 1. Install gas cap into fuel tank. |  Figure 1. Screw in Gas Cap | ||||
| 4. | To lock, push on gas cap and rotate clockwise one-eighth turn. To unlock, push down on gas cap and rotate counterclockwise one-eighth turn. | |||||
| 5. | Before removing adhesive backing, note position of notch on inside diameter of trim ring. NOTE As the trim ring is rotated, there will be gaps between trim ring and fuel tank. Rotate trim ring to position that best eliminates gaps between fuel tank and trim ring. | |||||
| 6. | See Figure 4. Determine best position of bottom trim ring against contour of the fuel tank. a. All kits except 61100133,
61100134: With notch (A) positioned toward the front of the motorcycle, rotate trim ring slightly to determine best position. b. Kits 61100133,
61100134: With notch (B) positioned toward the front of the motorcycle, rotate trim ring slightly to determine best position. |  Figure 2. Determine Position for Trim Ring | ||||
| 7. | See Figure 3. Mark position of trim ring with masking tape (1) or grease pencil. | 
Figure 3. Align Trim Ring and Press into Place | ||||
| 8. | Carefully cut masking tape at location (2) with a hobby knife making sure not to scratch trim ring or paint surface on fuel tank. | |||||
| 9. | Peel adhesive backing off trim ring. | |||||
| 10. | Using gas cap to center and masking tape (or grease pencil mark) to align, press trim ring firmly into position for about ten seconds. | |||||
| 11. | NOTE Allow trim ring to cure for about 5-7 minutes before continuing with kit installation. |
SERVICE PARTS
Figure 4. Service Parts: Flush-Mount Gas Cap Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Trim ring, chrome (for kit 63133-10B) | 63137-10 |
Trim ring, black (for kit 63134-10B) | 63138-10 | |
Trim ring, chrome (for kit 63139-10B) | 63141-10 | |
Trim ring, black (for kit 63140-10B) | 63142-10 | |
Trim ring, chrome (for kit 6110006B) | 63028-06 | |
Trim ring, black (for kit 61100007B) | 75015-08 | |
Trim ring, chrome (for kit 61100133) | 63045-06A | |
Trim ring, black (for kit 61100134) | 75004-08A | |
Trim ring, black (for kit 61100136) | 61100149 | |
Trim ring, black (for kit 61100210) | 61100151 | |
Trim ring, chrome (for kit 31100211) | 61100150 | |
2 | Fuel cap | Not Sold Separately |
3 | O-ring | 11900004 |
Items Mentioned in Text | ||
A | Square notch (used for all kits except 61100133, 61100134) | |
B | V notch (used for kits 61100133, 61100134, 61100210, 61100211) | |