Vacuum Operated Fuel Valve

M-1063A 1 of 3
GENERAL
As recently advised in the October 15, 1996 Mailgram (ML-
342), Harley-Davidson has become aware that the effects of
reformulated gasoline, along with certain usage of the vacuum
operated fuel valve (Part Nos. 61338-94, 61338-94A and
62169-95) could affect the supply of gas to the carburetor.
This condition required two factors: the use of reformulated
fuels containing MTBE, and starting the motorcycle with the
fuel valve handle in the OFF position. This could affect the operation
of the diaphragm in the fuel valve. The fuel flow could
become unpredictable in certain situations thus causing the
engine to shut down.
As a precautionary measure, Harley-Davidson has elected
to initiate a voluntary recall campaign in the interest of motor
vehicle safety and customer satisfaction. This voluntary
recall applies to:
1994 FL Touring Models
1995, 1996, 1997 XL, FX, FX/FL Softail, and FL Models
(equipped with vacuum operated fuel valves)
manufactured through September 30, 1996)
Attached is a list of all the motorcycles delivered to your
dealership that are involved in this campaign.
To ensure rider safety, it is your responsibility to perform the
required service on all effected motorcycles even if the
motorcycle was not purchased from your dealership. You will
be required to perform the required service on all effected
motorcycles in your dealership inventory prior to selling or
leasing those motorcycles.
If you are not sure that a safety recall has been completed
on a particular motorcycle, contact the Harley-Davidson
Recall Information Line at 1-800-448-1708 for a computer
check of our recall records.
IMPORTANT NOTE
Because only registered owners will receive notification from
us, we request that you contact any owners of motorcycles
still listed as unregistered. Advise them of the safety recall
and make arrangements for them to come in for recall
service. We also require that you provide us with their
names, addresses and VIN’s as soon as possible to enable
us to mail them an owner’s letter, as required by the National
Traffic and Motor Vehicle Safety Act (as amended).
The service required by this recall involves replacing the
original fuel valve diaphragm assembly with the diaphragm
assembly contained in the Recall Code 088 Kit (Part No.
93797). See Pages 2 and 3 of this bulletin for detailed
instructions.
SERVICE BULLETIN
M-1063A Safety Recall Code 088 November 1, 1996
VACUUM OPERATED FUEL VALVES

A partial shipment of Recall Code 088 Kits will begin on or
around November 7, 1996. All kits will be shipped no charge,
transportation paid. If additional kits are needed, please fill
out the attached order form and send it to the attention of the
Warranty Department.
The Recall Kit contains:
Qty Description
1 Diaphragm assembly
1 Fuel hose clamp
CREDIT PROCEDURES
Vehicle Repair
For each motorcycle repaired, completely fill out a Dealer
Service Card. Place a “C” in the letter box. If using the new
bar-coded card supplied to the customer with the
notification, affix your bar-coded dealer label in the
appropriate box (if label is available), otherwise simply write
your dealer number in the appropriate box. If using the old
style Dealer Service Card, be sure you supply all necessary
information, including VIN, your dealer number, and
dealership name and address.
When Harley-Davidson receives your properly completed
Dealer Service Card, you will be credited for 0.2 hours of
labor for performing the procedures outlined in this bulletin,
which includes 0.1 hour for dealer administration time.
Dealer Stock Parts
Remove all affected vacuum operated fuel valves, Part Nos.
61338-94, 61338-94A, and 62169-95, from your stock. To
receive credit, complete a regular Warranty Claim Form
referencing Service Bulletin M-1063 in the “Description of
Repair” section.M-1063A 2 of 3
GENERAL
Use the repair procedure below to replace the fuel valve’s
diaphragm.
Read the entire procedure before attempting
repair.
1
WARNING
To avoid personal injury, perform the following repair
procedure on a cold engine only. Do not smoke or allow
open flames anywhere in the area when working on fuel
system components. Gasoline is extremely flammable
and highly explosive under certain conditions.
REPAIR PROCEDURE
NOTE
There may be some minor fuel leakage during this
procedure. Place a shop rag under the valve as shown in
Figure 1 to catch any fuel.
See Figure 2 for Illustration of valve components.
1340 Models
1. Turn fuel valve lever to the OFF position and remove
vacuum hose from valve nipple.
2. Disconnect fuel hose from outlet fitting on valve body.
3. Loosen fuel valve hex fitting just enough (approximately
1/8 turn) to allow valve body to be rotated.
4. Turn valve body to the right until back of valve is
accessible, then tighten hex fitting to prevent fuel from
leaking.
5. Remove the four black screws with captured
lockwashers that hold the diaphragm cover in place.
6. Remove the diaphragm cover and coil spring. Note the
orientation of the original diaphragm as it sits in the
diaphragm frame. The replacement diaphragm will fit in
the frame the same way.
7. See Figure 2. Remove diaphragm frame from valve
body, then remove the diaphragm assembly from the
frame by pressing the small diaphragm end through the
frame.
8. See Figure 3. Install the new diaphragm assembly by
carefully inserting the small diaphragm end of the
assembly through the hole in the diaphragm frame. With
diaphragm assembly in place, make sure both large and
small diaphragms seat in diaphragm frame grooves.
9. Place diaphragm frame into valve body, small
diaphragm end first. Make sure the atmospheric port
points towards the bottom of the valve.
10. Place coil spring between frame and diaphragm cover,
then secure cover to valve body with the four black
screws with captured lockwashers. The vacuum nipple
points towards the top of the valve on 1340 models and
towards the bottom of the valve on Sportster models.
Tighten screws to 18.5 in-lbs (2 Nm).
11. Loosen hex nut and rotate valve body back into position.
Hold valve body and tighten hex nut to 15-20 ft-lbs (20-
27 Nm).
12. Reattach fuel hose to outlet fitting on valve, using the
new fuel hose clamp contained in Recall Kit, and
reattach vacuum hose to valve nipple.
Sportster Models
1. Turn fuel valve lever to the OFF position and disconnect
fuel hose from outlet fitting on valve body.
2. Loosen fuel valve hex fitting just enough (approximately
1/8 turn) to allow valve body to be rotated.
3. Rotate fuel valve 1/4 turn to make vacuum hose
accessible. Remove vacuum hose from vaccum port on
valve body.
NOTE
Depending on Sportster model, the fuel valve may need to
be rotated to either the right or left to access the back of the
valve.
4. Turn fuel valve lever to the RES position and rotate
valve body until back of valve is accessible, then tighten
fuel valve nut to prevent fuel from leaking.
5. Reach behind valve and turn fuel valve lever to the OFF
position.
6. Perform steps 5-10 under
1340 Models
.
Figure 1. Valve Body Rotated to Allow Access to
Diaphragm Cover Screws (1200 Sportster valve shown)
i00822
Shop rag
M-1063A 3 of 3
Figure 3. Valve Diaphragm Placed in Frame
6055
FRAME SIDE FACING DIAPHRAGM COVER FRAME SIDE FACING VALVE BODY
Atmospheric port
Seat for diaphragm Seat for diaphragm

Figure 2. Fuel Valve Components
i00823
Frame
Diaphragm
Coil spring
Diaphragm cover
VOES
vacuum
nipple
Valve body
7. Loosen hex nut, turn fuel valve lever to the RES
position, and rotate valve body back into position. Turn
fuel valve lever to the OFF position. Hold valve body and
tighten hex nut to 15-20 ft-lbs (20-27 Nm).
8. Reattach fuel hose to outlet fitting on valve, using the
new fuel hose clamp contained in Recall Kit, and
reattach vacuum hose to valve nipple.
M-1063B 1 of 2
General
Service Bulletin M1063A dated November 1, 1996 contains
general information along with the service procedure
pertaining to Safety Recall Code 088 Vacuum Operated Fuel
Valves. To aid in assembly we have included six alignment
pins and have developed additional steps to be used in the
service procedure. The additional steps are listed in this
bulletin and six alignment pins are attached.
There is no need to do this procedure on motorcycles which
have already had the 088 recall successfully performed.
Diaphragm Replacement
Complete Steps 1-7 as outlined in Service Bulletin M-1063A
and then continue with additional steps listed below.
NOTE
Diaphragm will install easily if small diaphragm is pinched in
half when inserted into frame.
8. Install the
new
diaphragm into the frame. Make sure
that the diaphragm edges are seated in the grooves in
the frame.
9. Install two alignment pins, provided in the service kit,
into the top left and bottom right holes of the fuel valve
body and tighten a few turns by hand.
10. Slide the diaphragm frame over the alignment pins and
up to the valve body, small end of the diaphragm first.
Make sure the atmospheric port points downward.
NOTE
Do not attempt to assemble diaphragm frame with spring
and cover without inserting onto pins. Install frame on pins
first, then position spring and cover.
11. While holding diaphragm frame firmly against valve body,
place coil spring and cover over the alignment pins and
slide them into position. Do not disturb the position of the
diaphragm, it must remain seated in the groove.
12. Install two cover screws in the two open holes in cover.
Tighten screws to 18.5 in-lbs (2.1 Nm).
13. Remove alignment pins and install remaining two cover
screws to cover. Tighten screws to 18.5 in-lbs (2.1 Nm).
14. Perform a vacuum test on the valve.
SERVICE BULLETIN
M-1063B Safety Recall Code 088 July 24, 1997
ADDENDUM TO FUEL VALVE SERVICE BULLETIN M-1063A
(SAFETY RECALL CODE 088)
®
Vacuum Test
Vacuum test the valve using the procedure below:
1. Connect PLASTIC MITY-VAC
®
HAND PUMP, Part No.
HD 23738, vacuum line and suitable vacuum fitting to
the vacuum port of the petcock.
2. Run a section of clear fuel line from the fitting on the
petcock to a gas can.
3. Pull 25 in. Hg vacuum and release. Check for fuel flow
while applying vacuum and check that fuel stops flowing
shortly after vacuum is released.
4. Repeat Step 3 five times, each time checking for fuel
flow at vacuum and no fuel flow shortly after vacuum is
released. On fifth application of vacuum, pause with
vacuum applied, and check for slow leaks. Release
vacuum.
5. If no leaks were present, go to Step 6. If leaks were
present, repeat replacement procedure.
6. Disconnect hand held vacuum pump and fuel line.
7. Loosen fuel valve hex fitting 1/8 turn and rotate valve to
the left. Tighten hex fitting.
8. Position
new
hose clamp on fuel hose and install fuel
hose to outlet fitting on valve body.
9. Install vacuum hose to valve nipple.