FLUSH MOUNT FUEL CAP

941000042019-08-21

GENERAL

Kit Number

61100131, 61100132

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

WARNING

Rider 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.

Kit Contents

See Figure 5 and Table 1.

INSTALL RIGHT SIDE

WARNING

When 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.

Remove stock gas cap from fuel tank.

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.

See Figure 1. Install gas cap into fuel tank.

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.

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.

See Figure 5. With the notch (A) positioned toward the front of the motorcycle, rotate trim ring slightly to determine best position of bottom trim ring against contour of the fuel tank.

Figure 1. Screw in Gas Cap

See Figure 3. Mark position of trim ring with masking tape (1) or grease pencil.

Carefully cut masking tape at location (2) with a hobby knife making sure not to scratch trim ring or paint surface on fuel tank.

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.

Peel masking tape off (or remove grease pencil mark) from trim ring and fuel tank.

Figure 2. Determine Position for Trim Ring

1	Masking tape
2	Cut masking tape

Figure 3. Align Trim Ring and Press into Place

INSTALL LEFT SIDE

1.	Remove OE left side cap, press down and rotate cap counter clockwise.
2.	See Figure 4. Remove existing left side bracket. a. Use a piece of fishing line or waxed dental floss long enough to grasp both ends. b. Position line or floss as close to tank as possible. c. Pull both ends away from tank to remove bracket. d. Remove residual adhesive and clean surface of tank using a mixture of equal parts of isopropyl alcohol and distilled water.	Figure 4. Bracket Removal
3.	NOTE Clean faux cap adhesive surface with a mixture of equal parts of isopropyl alcohol and distilled water. Before removing adhesive backing, note position of notch on inside diameter of faux cap.
4.	See Figure 5. With the notch (A) positioned toward the front of the motorcycle, rotate faux cap slightly to determine best position of bottom against contour of the fuel tank.
5.	NOTE Rotate faux cap to position that best eliminates gaps between fuel tank and faux cap. Mark position of faux cap with masking tape or grease pencil.
6.	Carefully cut masking tape between tank and faux cap with a hobby knife making sure not to scratch trim ring or paint surface on fuel tank.
7.	Peel adhesive back from faux cap.
8.	Using marks to align, adhere faux cap to tank and press firmly for about ten seconds.
9.	NOTE Allow faux cap to cure for about 5-7 minutes before continuing with kit installation. Remove masking tape or grease from faux cap and tank.

SERVICE PARTS

Figure 5. Service Parts: Flush-Mount Gas Cap Kit

Table 1. Service Parts

Item	Description (Quantity)	Part Number
1	Trim ring, chrome (kit 61100131)	61100150
1	Trim ring, black (kit 61100132)	61100151
2	Fuel cap, chrome (kit 61100131)	61100052A
2	Fuel cap, black (kit 61100132)	63136-10C
3	O-ring	11900004
4	Trim, chrome, faux cap (kit 61100131)	61100145
4	Trim, black, faux cap (kit 61100132)	61100147
Items Mentioned in Text
A	V-Notch