OVAL STYLE LOCKING FUEL CAP
941002852021-09-15
GENERAL INFORMATION
Table 1. General Information
Kits
Suggested Tools
Skill Level(1)
61100187
Safety Glasses, Torque Wrench
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Oval Style Locking Fuel Cap
Table 2. Kit Contents: Round Style Locking Fuel Cap
Verify that all contents are present in the kit before installing or removing items from vehicle.
Item
Qty
Description
Part No.
Notes
1
1
Fuel tank locking filler assembly w/gasket
61000630
2
1
Lockset, unkeyed (Includes items 4-6, 8)
Not sold separately
3
1
Clamp, hose
29379-08
4
1
Cylinder sub-assembly
Not sold separately
5
10
Tumbler spring
Not sold separately
6
24
Tumbler
Not sold separately
7
3
Cable strap
10006
8
1
Grease (not shown)
Not sold separately
Kluber Lubrication:
  • CENTOPLEX 1 DL 1 cc/1 mL/0.03 oz
  • Observe good industrial hygiene practices
  • Wash hands after handling
  • Keep out of eyes
  • Chemical Nature: Mineral oil, lithium calcium soap
GENERAL
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
WARNING
Keep gasoline away from ignition sources. Gasoline is extremely flammable and highly explosive and, if ignited, could result in death or serious injury. (00634b)
Installation Requirements
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 the year and model motorcycle is required for this installation and is available from:
REMOVE
1. See Figure 2. Remove tank console (1).
a. Remove screws (2).
2. See Figure 3. Remove existing fuel cap.
a. Cut hose clamp that secures vapor hoses to fuel cap.
b. Cut cable straps that secures connector (5) to vent lines.
c. Disconnect connector (5) from vehicle harness.
d. Disconnect vapor hoses (3).
e. Remove screws (1). Retain.
1Tank console
2Screw (3)
Figure 2. Tank Console
1Screws (6)
2Fuel cap assembly
3Vapor hose (2)
4Vapor hose connection (2)
5Connector
Figure 3. Fuel Cap Assembly Removal
INSTALL
Setting Key Lock
1. See Figure 4. On Original Equipment (OE) vehicle key, determine cut depth at each key station.
2. Write values into Table 3.
3. Refer to Table 3. Write key depth codes from Figure 4 based on cut depths measured.
NOTE
Cut depth codes to be second digit of tumble numbers.
a. Stations 8,5,4,1: These stations use tumbler #11-14.
b. Stations 7,6,3,2: These stations use tumbler #21-24.
4. See Figure 5. Install tumbler springs (5), see Figure 1 , into holes at stations 8,5,4 and 1 on side (A) of cylinder sub-assembly.
NOTE
Place a piece of tape or hold installed tumbler springs and tumblers with a finger to hold spring and tumblers in place before installation of springs and tumbler on opposite side of cylinder sub-assembly.
5. See Figure 5. Install tumblers (6), see Figure 1 , #11-14 in stations 8,5,4 and 1 per tumble numbers determined in Table 3.
6. See Figure 5. Install tumbler springs (5), see Figure 1 , into holes at stations 2,3,6 and 7 on side (B) of cylinder sub-assembly.
7. See Figure 5. Install tumblers (6), see Figure 1 , #21-24 in stations 2,3,6 and 7 per tumble numbers determined in Table 3.
8. See Figure 6. While holding tumblers fully in place, install key in assembled cylinder sub-assembly.
9. Verify that all tumblers are assembled correctly.
NOTE
When key is fully inserted, all eight tumblers should be flush with outer diameter of cylinder. Note tumblers that are not flush. If tumbler is high on the spring side, replace with next higher number tumbler. If tumbler is high on the opposite side, replace with next lower number tumbler.
10. Apply an even layer of grease around outer diameter of tumbler area.
ATumbler Station
115.55 mm (.612 in)
214.45 mm (.569 in)
312.35 mm (.486 in)
411.25 mm (.443 in)
59.15 mm (.360 in)
68.05 mm (.317 in)
75.95 mm (.234 in)
84.85 mm (.191 in)
BCut Depths
0.15 mm (.006 in) = Depth code 1
0.75 mm (.030 in) = Depth code 2
1.45 mm (.057 in) = Depth code 3
2.25 mm (.089 in) = Depth code 4
Figure 4. Key Code Diagram
Figure 5. Spring and Tumbler Install Locations
1Cylinder sub-assembly
2Tumblers, installed and flush
3Key
Figure 6. Assembled Lockset
Install Locking Fuel Cap
1. See Figure 7. If cap is latched before lock cylinder is installed, use screwdriver or other tool to press slider inside cap's lock hole while pulling cap up.
2. See Figure 8. Use screwdriver or other tool, press in locking tab (1) fully in order to properly seat lock cylinder.
3. See Figure 9. Orientate lock cylinder notch (1).
4. Push cylinder fully into fuel cap.
5. Release locking tab.
6. While continuing to push cylinder in, turn key back and forth slightly until locking tab fully extends and cylinder is latched.
NOTE
When turning key actuates the locking tab, it is acceptable to close cap and remove key.
7. See Figure 3. Install oval locking fuel cap assembly (2) with OE screws (1).
8. See Figure 10. Torque screw in sequence. Tighten.
Torque: 2.8–3.3 N·m (25–29 in-lbs)
9. See Figure 1. Install hose clamp (3) on vapor hose where OE clamp was removed earlier.
10. See Figure 3. Connect vapor hoses (3).
11. See Figure 3. Connect connector (5) to vehicle harness.
a. Secure to vent lines with cable straps.
12. See Figure 2. Install tank console.
a. Secure with OE screws. Tighten.
Torque: 3–4 N·m (27–35 in-lbs)
Figure 7. Cap Latch Slider
Figure 8. Locking Tab
Figure 9. Lock Cylinder Orientation
Figure 10. Oval Locking Fuel Cap Installed / Torque Sequence
Table 3. Key Lock Instructions
Station
Side
Measured Depth
Depth Code
Tumbler No.
1
A
1__
2
B
2__
3
B
2__
4
A
1__
5
A
1__
6
B
2__
7
B
2__
8
A
1__