CUSTOM FUEL TANK INSTALLATION KIT FOR XL - Harley
Contents
1. 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 6702 in 4 J04180 2 of 22. 8a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a J04180 2 Disconnect battery cables negative cable first IWIN NIN 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 3 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 4 See Figure 1 Remove the screws 1 fuel pump 2 and gasket 3 Discard the gasket and screws is03419 Figure 1 Fuel Pump and Gasket Removal INSTALLATION 1 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 2 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 1 of2 NOTE Be sure that wiring
3. cMOTOR HARLEY DAVIDSON WY J04180 INSTRUCTIONS REV 2006 06 16 CUSTOM FUEL TANK INSTALLATION KIT FOR XL 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 The rider s safety depends 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 00333a 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 1 Remove the seat according to the procedure in the appli cable Service Manual WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 0004
4. harness does not get pinched between fuel tank and frame during tank installation 3 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 is03415 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
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