BILLET LED FUEL GAUGE KIT - Harley
Contents
1. and later carbureted models the Gray wire 4 will not be used Cut the wire short and tape over the end with electrical tape The Phillips head screw can remain in the connection marked 3V and GR For 2004 and later fuel injected models fasten the Gray wire 4 ring terminal to the gauge connection marked 3V and GR For ALL models Tighten all four Phillips head screws to 4 7 in Ibs 0 4 0 9 Nm 4 See Figure 5 While carefully lowering the fuel gauge feed the wire harness down into the drain tube until the long Gray wire B and three short Orange Black Yellow White wires exit the hole at the bottom of the fuel tank J03491 At the bottom left side of the fuel tank mate the completed pin housing to the socket housing 117B disconnected in Analog Fuel Gauge Removal Step 3 Feed the connector into the tunnel capturing the conduit in the flexible clip at the bottom of the tank and if so equipped the clamp on the frame The long Gray wire with socket terminal in the new gauge harness was not found on the original gauge For 2001 2003 fuel injected models the Gray wire will not be used Cut the wire short and tape over the end with electrical tape Proceed to Final Assembly For 2004 and later carbureted models the Gray wire will not be used Cut the wire short and tape over the end with electrical tape Proceed to Final Assembly For 2004 and later fuel injected models the Gray wire will replace the Yel2. each of items 11 and 12 Not sold separately Cross 4 O ring fuel gauge 27730 04 5 Wiring harness 70015 04 6 Pin housing four way 72904 01BK Items common 10 Hardware kit Service only contains items 11 and 12 75003 04 to ALL kits 11 Phillips head screw 4 Not sold separately 12 e Star washer 4 Not sold separately Items mentioned in text but not included in kit A Sending unit connectors B Gray wire with socket terminal C Wire conduit D Pin terminals J03491 50f6 Figure 5 Service Parts LED Fuel Gauge Kits J03491 6 of 6
3. the correct cavities of the four way pin housing 117A removed from the O E analog fuel gauge in Analog Fuel Gauge Removal Step 4 See Figure 3 and the AMP MULTILOCK ELECTRICAL CON NECTORS INSTALLING SOCKET PIN TERMINALS section in the Service Manual For all other models Install the two wires with pin termi nals D into the correct cavities of the 2 way pin housing Figure 5 Item 9 from the kit See Figure 4 and the AMP MULTILOCK ELECTRICAL CONNECTORS INSTALLING SOCKET PIN TERMINALS section in the Service Manual is03810a Cavity 1 Orange wire Cavity 2 Open Cavity 3 Open Cavity 4 Black wire 5 Four way pin housing 72904 01BK BONS Figure 3 Four Way Pin Housing Viewed From Wire End is03810b oF O COME 1 Cavity 1 Orange wire 2 Cavity 2 Black wire 3 Two way pin housing 72902 01BK Figure 4 Two Way Pin Housing Viewed From Wire End 6 Atthe bottom left side of the fuel tank mate the completed pin housing to the socket housing 117B disconnected in Analog Fuel Gauge Removal Step 3 Feed the connector into the tunnel capturing the conduit in the flexible clip at the bottom of the tank and the clamp on the frame if so equipped Proceed to Final Assembly 3 of 6 ene WARNING 1 Apply a light coat of petroleum jelly or corrosion retardant material to the negative battery terminal Refer to the After installing seat pull upw
4. MOTOR HARLEY DAVIDSON WY J03491 INSTRUCTIONS REV 2006 09 21 BILLET LED FUEL GAUGE KIT GENERAL Kit Number 75086 04 75087 04 75090 04 and 75091 04 Models These LED Fuel Gauge Kits are designed to replace the original equipment O E analog fuel gauge that is mounted in a simu lated left side fuel tank cap Kits 75086 04 and 75087 04 have a Six Shooter style top to match Genuine Motor Accessory Billet Fuel Cap 62819 03 Kits 75090 04 and 75091 04 have a Cross style top to match Genuine Motor Accessory Billet Fuel Cap 62816 03 For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only NOTE The instrument panel mounted O E low fuel warning lamp function will be disabled when installing these kits Additional Tools and Service Manual Required A Terminal Pick Snap On TT600 3 or equivalent will aid in the installation of this kit 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 fo
5. ard on seat to be sure it is Service Manual and follow the instructions given to re locked in position While riding a loose seat can shift attach the negative battery cable and install the seat causing loss of control which could result in death or serious injury 00070b NOTE If the fuel gauge does not indicate the proper fuel level after installing this kit check the connectors then follow the trou bleshooting procedures in the Service Manual J03491 4 of 6 SERVICE PARTS Table 2 Service Parts Table Kit Item Description Quantity Part Number Kit 75086 04 1 Fuel gauge LED includes four each of items 11 and 12 Not sold separately Six Shooter 2 Medallion Bar and Shield logo 13883 00 4 O ring fuel gauge 27730 04 7 Wiring harness 70006 03 8 Wire lead Yellow White Not sold separately 9 Pin housing two way 72902 01BK Kit 75087 04 1 Fuel gauge LED includes four each of items 11 and 12 Not sold separately Six Shooter 2 Medallion Bar and Shield logo 13883 00 4 O ring fuel gauge 27730 04 5 Wiring harness 70015 04 6 Pin housing four way 72904 01BK Kit 75090 04 3 Fuel gauge LED includes four each of items 11 and 12 Not sold separately Cross 4 O ring fuel gauge 27730 04 7 Wiring harness 70006 03 8 Wire lead Yellow White Not sold separately 9 Pin housing two way 72902 01BK Kit 75091 04 3 Fuel gauge LED includes four
6. gure 1 Fasten the Orange wire 1 ring terminal to the gauge connection marked 12V and O with ascrew and washer Fasten the Black wire 2 ring terminal to the connection marked GND and BK with a screw and washer Fasten the Yellow White wire 3 ring terminal to the con nection marked Y W with a screw and washer is03808 Orange wire to 12V O Black wire to GND BK Yellow White wire to Y W Gently pull the wires to remove slack while installing the gauge to the fuel tank DO NOT twist the gauge during installation Hold the gauge firmly and press downward until it snaps into place NOTE DO NOT attempt to connect the Gray wire socket terminal into the four way pin housing 5 Install the three wires with pin terminals D into the correct cavities of the four way pin housing 6 from the kit See Table 1 and the AMP MULTILOCK ELECTRICAL CON NECTORS INSTALLING SOCKET PIN TERMINALS section in the Service Manual Table 1 Wire Chart Kits 75087 04 75091 04 Cavity Wire Color Cavity 1 Orange wire Cavity 2 Yellow White wire Cavity 3 Open Cavity 4 Black wire Penn Gray wire to 3V GR Figure 1 Wire Connections Kits 75087 04 75091 04 3 For 2001 2003 fuel injected models the Gray wire 4 will not be used Cut the wire short and tape over the end with electrical tape The Phillips head screw can remain in the connection marked 3V and GR For 2004
7. low White wire found in cavity 9 of the speedometer connector 39B Touring or Softail models or instrument assembly connector 20 Dyna models Connect the long Gray wire in the following manner a Route the Gray wire through the tunnel under the fuel tank then up the front of the tank b Follow the instructions in the Service Manual to gain access to the speedometer connector 39B Touring or Softail or instrument connector 20 Dyna c Locate the Yellow White wire in Cavity 9 of the con nector and remove the wire and terminal from the connector Refer to the PACKARD ELECTRICAL CONNECTORS section in the Service Manual 2of6 Following removal either cut the Yellow White wire short and tape over the end with electrical tape or fold the wire back on itself and tape over the end d Route the Gray wire to the connector and install into the now empty Cavity 9 Re install the rear cover of the speedometer or instrument assembly connector as required See the Service Manual e Install tape or wire ties along the path of the gray wire to secure it Proceed to Final Assembly LED Gauge Installation Kits 75086 04 and 75090 04 1 See Figure 5 Obtain the new LED fuel gauge 1 or 3 O ring 4 wiring harness 7 and separate Yellow White wire lead 8 from the kit Assemble the O ring to the fuel gauge 2 Four Phillips head screws 11 and four star washers 12 come pre assembled to the connections on the unde
8. ove the terminals from the pin housing 117A See AMP MULTILOCK ELECTRICAL CONNECTORS REMOVING SOCKET PIN TERMINALS in the Service Manual Discard the fuel gauge but save the pin housing for re assembly For all other models Use a pick Snap On TT600 3 to remove the terminals or clip off the wires The fuel gauge and pin housing can be discarded 5 For Carbureted Models Remove the fuel gauge by firmly grasping and carefully pulling up DO NOT twist just far enough to free the gauge from the fuel tank Disconnect the two sending unit connectors Feed the conduit and two wires up through the tube while removing the gauge Remove and discard the fuel gauge For Fuel Injected Models Remove the fuel gauge by firmly grasping and carefully pulling up DO NOT twist on the gauge to free it from the fuel tank Feed the conduit and three wires up through the tube while removing the gauge Remove and discard the fuel gauge 6 Remove and discard the rubber gasket Proceed to LED Gauge Installation for the kit being installed LED Gauge Installation Kits 75087 04 and 75091 04 1 See Figure 5 Obtain the new LED fuel gauge 1 or 3 O ring 4 and wiring harness 5 from the kit 1 of 6 Assemble the O ring to the fuel gauge 2 Four Phillips head screws 11 and four star washers 12 come pre assembled to the connections on the underside ofthe gauge Remove the screws and washers to connect the wires as follows See Fi
9. r this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 5 and Table 2 INSTALLATION WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable Retain all seat mounting hardware J03491 WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a Analog Fuel Gauge Removal NOTE The fuel gauge wires are routed through a tube in the fuel tank and are secured by a clip at the bottom of the tank and on some models a clamp on the frame Open the clip and clamp as needed and be sure there is enough slack in the wires to be able to lift out the gauge 2 At the bottom left side of the fuel tank bend back the flexible clip slightly to free the fuel gauge conduit Open the harness clamp on the frame if necessary to free the conduit Gently pull on the conduit to draw the Multilock connector 117 out of the tunnel 3 See Figure 5 Depress the pin on the socket housing side of the connector and pull apart the pin and socket halves 4 For 2001 2002 Carbureted FLHR models Use a pick Snap On TT600 3 to rem
10. rside of the gauge Remove the screws and washers to connect the wires as follows See Figure 2 Fasten the Orange wire 1 ring terminal to the gauge connection marked 12V and O with a screw and washer Fasten the Black wire 2 ring terminal to the connection marked GND and BK with a screw and washer Fasten the ring terminal from the separate Yellow White wire 3 to the connection marked Y W with a screw and washer The screw and washer can remain in the connection marked 3V and GR 4 is03809 Orange wire to 12V O Black wire to GND BK Yellow White wire to Y W Screw and washer to 3V GR Penn Figure 2 Wire Connections Kits 75086 04 75090 04 J03491 3 Tighten all four Phillips head screws to 4 7 in Ibs 0 4 0 9 Nm 4 See Figure 5 While carefully lowering the fuel gauge feed the wire harness 7 and Yellow White wire lead 8 down into the drain tube until the two longer Black Orange wires with pin terminals D exit the hole at the bottom of the fuel tank Connect the two shorter wires Black and Yellow White to the sending unit connectors see Analog Fuel Gauge Removal Step 5 Gently pull the long wires to remove slack while installing the gauge to the fuel tank DO NOT twist the gauge during installation Hold the gauge firmly and press downward until it snaps into place 5 For 2001 2002 carbureted FLHR models Install the two wires with pin terminals D into
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