NHTSA ID Number: 10164794
Manufacturer Communication Number: M1493
TSB/Document Date: 2019-09-16
Summary
SERVICE BULLETIN M1493: FUEL CAPS AND CUP CHANGE. REVISION. PURPOSE: This bulletin informs dealers that Harley-Davidson
is making a fuel tank running change on side fill Touring, Police Touring, Touring CVO, Trike and all Softail and Sportster platforms. This running change is starting May 22, 2019. Service parts for Dyna tanks and fuel caps are also covered by this bulletin. The running change is to the thread pitch in the fuel cap and in the fuel cup. The running change will affect OE (Original equipment) and P&A (Parts and Accessories) parts. All new fuel tanks and caps are retrofittable to previous years. Fuel caps from previous years will not fit on a new fuel tank.
M1493
2019-08-23
M1493: FUEL CAPS AND CUP CHANGE
Reason for Revision
1349457
Refer to Table 1.
Table 1. Document History
Date
Revision Description
2019-05-29 Initial release
Torque reference
* Updated Softail Platform
Screw Qty.
2019-08-23
* Updated Softail Platform : Table 2
Part number
* Updated Warranty : Table 3
Purpose for Service Bulletin
This bulletin informs dealers that Harley-Davidson is making a
fuel tank running change on side fill Touring, Police Touring,
Touring CVO, Trike and all Softail® and Sportster platforms.
This running change is starting May 22, 2019.
Service parts for Dyna tanks and fuel caps are also covered
by this bulletin.
Additional Information
The running change is to the thread pitch in the fuel cap and
in the fuel cup. The running change will affect OE (Original
equipment) and P&A (Parts and Accessories) parts. All new
fuel tanks and caps are retrofittable to previous years.
Figure 1. New Fuel Cap (Typical)
Fuel Tank
Touring, Dyna and Sportster Platforms
See Figure 2. To identify the new fuel tanks for Touring and
Sportster platforms, the fuel cup will have a stamped R code
in it. Depending on the platform the code is:
• Touring: R 090
• Sportster, Dyna: R 091
1349498
Fuel Cap
Fuel caps from previous years will not fit on a new fuel tank.
See Figure 1. Fuel caps that can be used on all early and later
year tanks have a notch in the bottom part of the cap. Refer to
Table 3.
Figure 2. Fuel Tank Cup: Sportster and Dyna Shown,
Touring Similar
NOTE
In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service.
ROUTING
INITIAL HERE
SERVICE
MANAGER
SALES MANAGER PARTS MANAGER
WARRANTY
PROCESS
MANAGER
LEAD TECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO
Softail Platform
Table 2. Screw
See Figure 3. To identify the new fuel tanks for Softail platform,
the fuel tank cup (2) will no longer be equipped with upper vents
(3) or a ring (1).
Part No.
10500098 (Previous)
10500167 (New)
Item
Description
Qty
Screw
2
3
1350685
1350800
1
2
1
3
2
1.
2.
3.
Ring
Fuel tank cup
Upper vent
Figure 3. Previous Softail Fuel Tank
1.
2.
Fuel tank
Screws
Figure 4. Fuel Tank - Screws (Typical)
See Figure 4. On the 2018 and 2019 Softail platform fuel tank
(1) Harley-Davidson is changing the screws (2). The previous
screws can not be used on the new fuel tank due to the new
sizing of the screws. The new screws (Part No. 10500167) can
only be used on the new fuel tank. Refer to Table 2.
Markets Affected
The new screws (Part No. 10500167) has updated torque
values.
For vehicles or P&A fuel tanks within their factory warranty
period only:
14.9–17.6 N·m (11–13 ft-lbs)
2/3
All markets are affected.
Warranty
• In the event a fuel tank needs to be replaced for a warranty
concern, Harley-Davidson will cover the associated updated
P&A fuel cap only if the fuel cap is registered to the VIN
(Vehicle identification number) as part of the Custom
Coverage program or is within the over-the-counter warranty
period.
M1493
Table 3. Fuel Cap Replacement
New
Number
61100052A
61100117A
61100123A
61100107A
61100093A
61289-07C
63136-10C
61100124A
63133-10B
75014-06D
61100006B
62818-06G
61100122A
61100126A
61100176
62823-06D
61100106A
61100129A
63134-10B
61100007B
61100076A
61100103A
75027-08D
62910-09D
63140-10B
61272-92E
75327-09D
62910-06D
61100127A
62823-08D
63139-10B
61100120A
61100125A
M1493
Description
CAP,FUEL,FLUSH MT,CHROME
KIT,FUEL FILL,BLACK,LOCKING
CAP,FUEL,&KEY ASSY,LOCKING,CHRM,CHN
KIT,FUEL FILL,BLACK
CAP,FUEL,RH-THD,FILLER,BLK
CAP,FUEL,RH-THREAD,FILLER,SATIN
CAP,FUEL,FLUSH MT,BLK
CAP,FUEL,&KEY ASSY,LOCKING,BLACK,CHN
KIT,FUEL FILL,CAP,FLUSH MT,3.3G,CHRM/SPR
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH,BLK/SFT
KIT,FUEL FILL,CAP,FLUSH MT,CHRM/SFT
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH/SFT
CAP,FUEL,&KEY ASSY,LOCKING,BLACK
KIT,FUEL FILL,BLACK DIAMOND
CAP,FUEL,BLACK DIAMOND
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH/FLHR
KIT,FUEL FILL,BRONZE
KIT,FUEL FILL,LOCKING,CHROME
KIT,FUEL FILL,CAP,FLUSH MT,3.3G,BLK/SPR
KIT,FUEL FILL,CAP,FLUSH MT,BLK/SFT
KIT,FUEL FILL,BRASS
KIT,FUEL FILL,WILLIE G SKULL,BLACK
KIT,FUEL MISC CMPNT,CAP&GA,FLSH,BLK/FLHR
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH/DYN
KIT,FUEL FILL,CAP,FLUSH,4.5/2.1G,BLK/SPR
CAP,FUEL,RH-THREAD,FILLER,CHROME
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH,BLK/DYN
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH/DYN
KIT,FUEL FILL,AGITATOR
KIT,FUEL MISC CMPNT,CAP&GA,FLUSH/FLHR
KIT,FUEL FILL,CAP,FLUSH,4.5/2.1,CHRM/SPR
CAP,FUEL,&KEY ASSY,LOCKING,CHRM
KIT,FUEL FILL,WILLIE G SKULL,CHROME
Replaces
61100052
61100117
61100123
61100107
61100093
61289-07B
63136-10B
61100124
63133-10A
75014-06C
61100006A
62818-06F
61100122
61100126
61100126
62823-06C
61100106
61100129
63134-10A
61100007A
61100076
61100103
75027-08C
62910-09C
63140-10A
61272-92C
75327-09C
62910-06C
61100127
62823-08C
63139-10A
61100120
61100125
3/3
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TSB/Document ID: M1493
Replacement Service Bulletin Number:
MFR Communication Date: 2019-08-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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