flht oil pressure and air temperature gauge kit
Contents
1. Insert tapered end of secondary locking wedge into the pin housing and press down until it snaps in place The wedge fits in the center groove within the pin housing and holds the terminal latches tightly closed 12 Remove original oil pressure sending unit from crankcase with a 15 16 inch open end crow foot wrench 13 Apply LOCTITE 565 Thread Sealant to threads on the new oil pressure sending unit 14 See Figure 9 Start the oil pressure sending unit 7 into crankcase bore Tighten switch to 8 10 ft lbs 11 14 Nm with a 1 1 16 inch open end crow foot wrench 15 Attach connector to oil pressure sending unit Gauges 1 Follow applicable Service Manual instructions to remove the outer fairing 2 Remove plastic plugs from the gauge holes in inner fairing 3 See Figure 9 Install gauges 1 and 2 in the inner fairing While seated on the motorcycle the air temperature gauge installs in the hole on the left side of the radio tray and 2 of 4 the oil pressure gauge installs in the hole on the right side of the radio tray 4 For each gauge slide back clamp 4 over the gauge studs Verify that the tab A or B on bracket engages slot at bottom of inner fairing bore 5 Loosely install hex nuts 5 on studs Verify that the gauge is properly aligned and then tighten nuts securely 6 For 2000 2007 Models See Figure 6 Install the air tem perature sensor in the location shown 2 by pushing the post on the connecto2. cMOTOR HARLEY DAVIDSON WB J01875 INSTRUCTIONS REV 2007 04 02 FLHT OIL PRESSURE AND AIR TEMPERATURE GAUGE KIT GENERAL Kit Number 77439 00 Complete Kit 77459 00 Installation Hardware Only No Gauges Models 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 Additional Parts Required Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle Please see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only for a list of required parts or accessories for your model Separate purchase of LOCTITE 565 Thread Sealant is required for proper installation of this kit LOCTITE can be purchased from any Harley Davidson Dealer 2004 and Later Models Do not require installation of items 6 7 and 8 from 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 r
3. equired for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 9 and Table 1 INSTALLATION Oil Pressure Sending Unit 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 battery cables negative cable first J01875 is04574 Oil pressure sending unit Cam position sensor Crank position sensor Main harness to ECM Oe Figure 1 Electrical Bracket 2000 2001 Fuel Injected Models Magnetti Marelli is04575 1 Oil pressure sending unit 2 Crankshaft position sensor 3 P amp A siren kit Figure 2 Electrical Bracket ECM Removed 2002 2003 Fuel Injected Models Delphi 1 of 4 NOTE For 2002 to 2003 models See Figure 2 Remove the two screws securing the ECM and remove the ECM to access the electrical bracket 2 For 2004 and later models Proceed to the Gauges section For 2000 to 2003 models See Figure 1 Figure 2 and Figure 3 for the applicable model and locate the sensor harness connector 2 piece mini Deutsch connector is04576 Ignition harness Cam position sensor Oil pressure sending unit Crankshaft position sensor Pena Figure 3 Ignition Module Carbureted Models 3 Locate the oil pressure sendi
4. er to the Service Manual and follow instructions to install the seat J01875 is04580 CHINA 1148 4 lt E 1078 107A Oil pressure Air temperature Lead wires from interconnect harness AOD a Air temperature sensor Figure 8 Wiring Schematic 3of4 SERVICE PARTS is04581 Figure 9 Service Parts FLHT Gauge Kit Table 1 Service Parts Table Conduit Item Description Quantity Part Number Air temperature gauge 75109 96B 2 Oil pressure gauge 75032 99A 3 Air temperature sensor 74419 96A 4 Back clamp 2 inch 2 67352 96 5 Metric hex nut 4 67043 96 6 Jumper oil pressure gauge 32806 00 7 Sending unit oil pressure 74438 99 8 Not Sold Separately Items mentioned in text but not included in kit z Light bulb replacement 67445 00 A Alignment tab B Alignment tab J01875 4 of 4
5. ng unit at the front right side of the crankcase and pull wire socket from terminal of the oil pressure sending unit 4 Carefully draw the conduit and the pin side of mini Deutsch connector forward and then up between the rear brake master cylinder reservoir and the frame downtube to area of the rear brake pedal 5 See Figure 4 Remove the secondary locking wedge 3 from the pin side of the connector with a needle nose pliers 6 Gently depress terminal latches inside pin housing and back out the pin in chamber 1 through the hole in wire seal 7 Pull the oil sending unit wire through conduit and remove wire Note the routing of the wire 8 See Figure 9 Route the jumper 6 pins through the con duit from the kit in the same direction as the original wire noted in Step 7 Use cable straps to secure to the wire bundle 9 See Figure 5 Locate pin chambers 1 and 2 on pin side of connector Insert brown green jumper pin into chamber 2 and feed until it clicks into place Verify that pin will not back out of the chamber by giving a slight tug on the wire to confirm that it is locked is04578 1 Sending unit jumper wires is04577 1 Pin 2 Wire seal 3 Locking wedge Figure 4 Deutsch Connector Pin Side 2 pin connector shown J01875 Figure 5 Route Oil Sending Unit Connector 10 Insert green yellow jumper pin to chamber 1 and repeat steps performed in Step 9 11
6. r into the hole in the fairing support For 2008 and Later Models See Figure 7 Remove frame plug 1 Push sensor post into hole to install sensor Secure wire harness with cable strap from the kit is04579 e 6 aaa TE 000 000 1 Air temperature gauge 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 is04582 1 Frame plug 2 Air temperature sensor 3 Steering head Figure 7 Location of Air Temperature Sensor 2008 and Later Models 2 Air temperature sensor location Figure 6 Location of Air Temperature Sensor outer fairing removed 2000 2007 Models 7 See Figure 8 Refer to the wire colors on the schematic to locate interconnect wire harness connectors 112 113 114 115 and 107 Mate interconnect wire harness con nectors to the gauges and sensor as shown in the schematic 8 Follow applicable Service Manual instructions to install the outer fairing 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 9 Refer to the Service Manual and follow the instructions given to install the battery positive cable first 10 Ref
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