PDF - Harley
Contents
1. 5 and secure with screws and washers 4 10 Refer to applicable Service Manual and install seat Awarnine After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shifti during vehicle operation resulting in loss of control of vehicle and death or serious injury Final Checks and Adjustments 1 See Figure 9 If necessary adjust the handlebar to the rider s normal position Hold the handlebar and loosen rear clamp bolts Position and adjust handlebars and tighten rear screws to 12 15 ft lbs NOTE When handlebar installation is complete the upper and lower clamps have contact with the cast in boss in front and have a slight gap at the rear WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 2 Connect the battery cables positive cable first 3 Turn ignition light switch to ON Check that the indicator lights signal lights and headlamp all function properly 4 Start the engine check the tachometer operation and check that the indicator lights are working correctly 5 If tachometer does not function see Figure 12 and check that all wiring connections were correctly made 6 Test ride motorcycle to verify soeedometer is functioning properly 6 of 7 SMOTOR2. e Part No 67359 96A Date 1 99 Service Parts ae XL Custom Tachometer Kit 11 3 Description Part No Description Part No Cable strap 4 10006 1 2 in vinyl conduit 9 in long not sold Screw cover 2 2548 6 place socket housing 72081 99 Gasket rear 67104 95 Orange wire 68944 98 Gasket front 67121 95 Socket Amp socket Tachometer 67152 99 Pink wire 68946 98 Speedometer amber bulb assy 67385 98 Socket Amp socket not shown Black wire 68947 98 Bracket speedo tach 67360 96 Socket no terminal Cover tach rear 67363 96 Pink wire Spacer 2 67366 96 Socket Deutsch 68987 99 Butt splice blue 70586 93 Screw hex socket 876A 5 16 18 x 2 1 2 i 2 It 1 2 3 4 5 6 7 8 9 1 1 oO not shown See Figure 10 for instructions on assembling connector wires and conduit into a harness J01482 7 of7
3. Screws 2 3 Rear cover 4 Gasket rear 6 Speedometer 7 Stock bracket Do not tug on the wire until the tang is released or the ter minal will be difficult to remove A click is heard if the tang is engaged but then inadvertently released Repeat the step without releasing the tang 5 Slide the wires removed in step 4 above out of the plastic conduit covering the wires connected to connector 20 1999 AND LATER MODELS 1 Refer to the Deutsch Electrical Connector section in Section 7 of the 1999 or later XLH Service Manual Depress external latches on socket half of connector and separate socket and pin halves Follow REMOVING INSTALLING SOCKETS instructions and remove the following wires from connector 20 Wire Color Cavity Number Orange white 1 White green 2 Black 12 Brown Violet 11 2001 and later models only 2 Slide the wires removed in step 1 above out of the plastic conduit covering the wires connected to connector 20 REMOVING SPEEDOMETER FROM STOCK BRACKET 1 See Figure 8 Unscrew boot 1 if necessary from Figure 8 Removing Speedometer From Stock Bracket Insert speedometer in double bracket making certain slots in speedometer are aligned with anti rotational tabs Place rear gasket in position and align gasket tabs with anti rotational tabs Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into
4. 1 Front View With Riser Cover Removed proceeding Inadequate safety precautions could result in death or serious injury WARNING Always disconnect the negative battery cable first If the positive battery cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious personal injury See Figure 1 Remove and discard handlebar clamp screws securing speedometer bracket Gently move speedometer forward and hang from mirror with cable strap N Refer to applicable Service Manual and remove seat and fuel tank following Service Manual procedures Fuel tank only needs to be removed on 1998 and earlier models WARNING Gasoline is extremely flammable and highly explosive When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Inadequate safety precautions can result in death or serious injury 3 See Figure 2 Remove two bolts and washers 4 securing upper fork bracket cover 5 Remove six screws 1 that secure front 2 and rear 3 riser covers i00591 Screws 6 Front riser cover Rear riser cover Screw and washer 2 6 Electrical panel 7 Upper fork bracket Figure 2 Removing Riser Covers 1of7 Remove rear riser cover 3 and front riser cover 2 See Figures 1 and 2 Note how electrical harnesses and connectors are positioned on the front and rear of the
5. For 1998 and earlier models replace speedometer bulb For 1999 and later models reconnect wire harness from Check that reset switch is in position and that all wires are positioned so they will not be pinched by rear cover 2 at bottom of bracket 3 position at the opposite side with bulb and boot included in kit back of speedometer 4 5 Install rear cover on speedometer install cover screws and reset switch boot ASSEMBLING TACHOMETER HARNESS 1 See Figure 10 As dictated by model year assemble one of the harnesses shown from wires conduit and connector provided in kit The connector cavity numbers are shown on socket housing 13 and wires must be inserted as follows speedometer reset switch by turning it counterclockwise Remove two cover screws 2 and the rear cover 3 For 1999 and later models disconnect wire harness from back of speedometer 2 Note position of rear speedometer gasket 4 and remove it Gently push on rear of speedometer while simultaneously pulling soeedometer and front gasket from bracket 3 Do not remove front gasket 5 from the speedometer 6 INSTALLING SPEEDOMETER IN DOUBLE BRACKET NOTE The tachometer will be mounted in the right side of the double bracket as received in the kit 1 See Figure 9 Feed wires from speedometer through front of left opening in double bracket Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installati
6. MOTOR HARLEY DAVIDSON WY J01482 INSTRUCTIONS REV 3 13 00 Kit Number 67359 96B XL TACHOMETER KIT General This kit is designed for installation on 1996 and later XL 1200 Custom models and 1999 and later XL883 Custom models equipped with an electronic speedometer and no tachometer NOTE Service Manuals for your model motorcycle are available from your Harley Davidson dealer WARNING SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury Installation GENERAL To install this kit you must remove the speedometer bracket and speedometer before removing the fuel tank You will also have to remove the seat disconnect the electronic speedometer harness from connector 65 under the seat and disconnect connector 20 between handlebar risers Read all the instructions carefully before you begin the tachometer installation Connector numbers in brackets 20 are the identifying numbers used in wiring diagrams Removal ELECTRONIC SPEEDOMETER AND BRACKET WARNING To protect against shock and accidental start up of vehicle disconnect the negative battery cable before f Electrical J panel L a oul Figure
7. correspond to items listed in Service Parts JO1482 4of7 i00237 Three wire speed sensor e harness not shown See Figure 11 for details of ground splice Socket No 1 10 See socket housing below for lead location in socket housing f1287b2x Socket housing as viewed from terminal end SOCKET NO WIRE COLORS OR MARKING 1 Orange white White green BN RT Brown right turn indicator W HB WHITE High beam V LT Violet left turn indicator Orange white 7 Pink 8 TN N Tan neutral indicator 9 GN Y OP Green yellow oil pressure 10 O or BE Orange or blue 11 BK black 12 BK black ground for speedo and tach Figure 12 Speedometer Tachometer Wiring Diagram NOTE The indicator light wires socket no 3 4 5 8 9 10 and 11 are all black To identify the mating wire color in pin housing and the circuit function the wires are marked with white letters giving color and circuit function NOTE On 1998 Models the 12 place connector 20 was replaced with a 14 place connector 20 Wires 1 12 are the same for both the 12 place and the 14 place connectors J01482 NOTE On 1999 and later models connector 20 was replaced with a 12 place Deutsch connector Location of wires 1 12 are the same as shown above NOTE On 2001 and later models socket number 11 is brown violet 5 of 7 the large conduit so the terminals are positioned ne
8. elec trical panel Figure 3 Removing Connector 20 1996 connector shown 1298x2x Socket terminal Secondary lock Pick tool Snap On TT600 3 aa 1 Open secondary lock 2 Insert pick into cavity 3 Pivot end of pick to release tang 4 Gently tug on wire to remove terminal Figure 4 Amp Multilock Socket Connector Wire Removal i00577 Cavity B White 1 Socket terminal and wire 2 Wire seal 3 Socket housing 4 External latch 5 Internal seal 6 Secondary lock Cavity C Black Figure 5 3 Place Deutsch Socket Connector J01482 f1050a8x NOTE Pin connector half shown Latches identical on socket half connector Figure 6 Depressing Terminal Latches 6 See Figure 3 Slide connector 20 down to disengage attachment groove 7 See Figure 4 Press the button on connector 20 to unplug 1998 AND EARLIER MODELS 8 Follow the speed sensor harness connected to speedometer that is routed down frame backbone to con nector 65 under seat 9 Slide connector 65 forward to disengage connector from T stud 10 See Figure 5 Depress external latch 4 and unplug the connector 11 Remove the secondary locking wedge 6 as follows Insert the blade of a small screwdriver between the socket housing 3 and locking wedge 6 inline with the socket holes Turn the screwdriver 90 degrees to pop the wedge up 12 See Figure 6 Gently depress terminal latches inside sock et h
9. on J01482 Wire Color Cavity Number Orange 1 Black 2 Pink 3 2 This harness will plug directly into the back of the tachometer After plugging wire ends into connector as shown cover wires with conduit from kit 5 Install rear cover on tachometer Install cover screws CONNECTING SPEEDOMETER TACH GROUND LEADS 1 Cut speedometer black ground lead 1 in from existing terminal Strip 3 8 in insulation from both the wire ends adjacent to the cut Strip 3 8 in insulation from tachometer black ground lead item 16 in Service Parts Illustration See Figure 11 Using one of the butt connectors from the kit connect the ground leads as shown Refer to SEALED BUTT CONNECTORS in the Service Manual for a complete procedure 3 of 7 1 Speedometer 2 Tachometer 3 Tachometer speedometer bracket 4 Spacer 2 5 Screw 5 16 18 x 2 1 2 in 6 Washer stock 7 Upper handlebar clamp i01288a i00235 1996 thru 1998 z utt connector 1999 and later 5 oe Same as Tachometer 1996 to 1998 tir ground wire but clip terminal off Orange wire Socket terminal end 14 amp use pink Figure 11 Connecting Tachometer amp Speedometer Grounds wire 17 CONNECTING SPEEDOMETER TACHOMETER LEADS TO CONNECTOR 20 1 Tape the three or four speedometer wires with the socket terminals on their ends together and slide them through Be Figure 10 Connecting Harness to Tachometer Callouts
10. ousing and back out sockets through holes in rear wire seal Cavity letters and wire colors are shown in Figure 5 Cavity letters are molded in the housing 13 Carefully note how the speed sensor harness is routed Pull the speed sensor harness forward through the cable straps Cut cable straps only if required 14 Cut cable strap holding speedometer and bracket to mir ror Place the speedometer and bracket on a clean work bench REMOVING SPEEDOMETER LEADS FROM CONNECTOR 20 1998 AND EARLIER MODELS 1 See Figure 4 Bend back the latch slightly and free one side of secondary lock then repeat the step to release the other side Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing 2 Looking in the terminal side of the connector opposite secondary lock take note of cavity next to each terminal 3 See Figure 7 Remove the following wires and terminals from connector 20 by following the procedure in step 4 Wire Color Cavity Number Orange white 1 White green 2 Black 12 4 See Figure 4 With the flat side of pick tool against the ter minal insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick away from the termi nal and gently tug on wire to pull terminal from chamber 2 of 7 1287b2x Secondary Locks Open i00590 5 Gasket front Figure 7 Terminal Numbers Stamped On Secondary Locks 12 place socket housing shown 2
11. tall locking wedge in Deutsch socket housing 20B on 1999 and later models INSTALLING SPEEDOMETER TACHOMETER 1 Hang speedometer tachometer assembly on mirror with cable strap and connect wiring as follows 1998 AND EARLIER MODELS 2 Route speedometer 3 wire harness back to its original position See Figure 5 Insert wires and terminals into connector 65 3 See Figure 13 Install secondary lock with arrow positioned as shown NOTE If the secondary lock wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The secondary lock indicates when terminals are not properly installed by not entering its fully installed position 4 Install cable straps to replace any that were removed 5 Mate halves of connector 65 6 Refer to applicable Service Manual and install fuel tank FOR ALL MODELS 7 See Figure 9 Install soeedometer tachometer assembly on handlebar clamp as shown using spacers and fasteners from kit Tighten screws snug tight J01482 x0014a7x housing Arrow must point to external latch housing Figure 13 Secondary Lock Positioning See Figure 3 Connect and install connector 20 on electrical panel See Figures 1 and 2 Position harnesses on electrical panel so they will not be pinched by riser covers See Figure 2 Install front 2 and rear 3 riser covers and secure with screws 1 9 Install cover
12. xt to theconnector 20 Place the tachometer harness next to the connector also NOTE Make certain the slot in the terminal faces the tang in the chamber for proper installation On the socket side of the connector tangs are at the top of each chamber so the socket terminal slot on the same side as the crimp tails must face upward Up and down can be determined by the position of the release button used to separate the pin and socket halves the button always being the top of the connector 2 For 1998 and earlier models Remove tape from the speedometer wires and insert the terminals into connector 20 as follows Instrument Wire Color Cavity Number Speedometer Orange white 1 Speedometer White green 2 Speedometer Black 12 Tachometer Orange white 6 Tachometer Pink 7 See Figure 12 for cavity number location For 1999 and later models Insert the terminals into Deutsch connector 20 as listed for 1998 and earlier models however since there is not an open cavity in the connector 20 for 1999 and later models the Orange wire will need to be spliced into the Orange White wire coming out of the speedometer at a convenient location Refer to SEALED BUTT CONNECTORS in the Service Manual for a complete procedure For 2001 and later models The brown violet wire needs to be inserted into cavity 11 3 After all wires are in place close the secondary locks on the socket housing 20B on 1998 and earlier models or ins
Download Pdf Manuals
Related Search