CUSTOM FUEL TANK INSTALLATION KIT FOR XL

J041802006-06-16

GENERAL

NOTE

Installation of a Custom (larger) tank will require the installation of an XL Custom seat. The standard seat on 883STD and 1200R models will not fit properly with the Custom (larger) tank.

The Custom fuel tank is stock on XL 883C and 1200C models.

Models

Table 1. Models

Kits	Models
62999-07	2007 and later XL 883STD, 883R, 883L, and 1200R

This kit is designed for the installation of a Custom (larger) color-matched tank (purchased separately).

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 2 and Table 2.

REMOVAL

Remove the seat according to the procedure in the applicable Service Manual.

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

WARNING

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

Disconnect battery cables, negative cable first.

WARNING

Stop 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)

Remove the fuel tank according to the procedure in the applicable Service Manual.

WARNING

With fuel tank drained, gasoline can spill from bore when supply valve is loosened or removed. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00277a)

See Figure 1. Remove the screws (1), fuel pump (2), and gasket (3). Discard the gasket and screws.

Figure 1. Fuel Pump and Gasket Removal

INSTALLATION

Install the original fuel pump and new gasket into the new fuel tank according to the procedures in the applicable Service Manual, using hardware supplied in the kit.
See Figure 2 and Table 2. Install the right (6) and left (7) fuel tank mount trim onto the new fuel tank front mounting tabs.

NOTE

Be sure that wiring harness does not get pinched between fuel tank and frame during tank installation.

Install the fuel tank according to the procedure in the applicable Service Manual, using hardware supplied in the kit. Front Tank Mount: Secure the front tank mount using 5/16-18 x 4-1/4 in. hex screws (2), two flat washers (5) and one 5/16-18 locking nut (8). Rear Tank Mount: Secure the rear tank mount using 5/16-18 x 3-1/2 in. hex screw (1), two flat washers (5), and one 5/16-18 locking nut (8).

WARNING

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

Connect the battery cables, positive cable first.
Install a new seat designed to fit XL883C/XL1200C model motorcycles according to the Instruction Sheet included with the seat kit.

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)

SERVICE PARTS

Figure 2. Service Parts

Table 2. Service Parts Table

Item	Description (Quantity)	Part Number	Item	Description (Quantity)	Part Number
1	Screw, Hex Socket, 5/16-18 x 3-1/2 in.	4758A	6	Trim, Fuel Tank Mount, Left	70903-04
2	Screw, Hex Socket, 5/15-18 x 4-1/4 in.	4771	7	Trim, Fuel Tank Mount, Right	70919-04
3	Fuel Line Kit	27693-07	8	Nut, Flanged, Locking, 5/16-18 (2)	7531
4	Fuel Pump Seal	75301-07	9	Screw, Torx, Button Head w/ Washer	1081
5	Washer, Flat, 5/16 in. x 11/16 in. x 1/16 in. (4)	6702