FUEL LEVEL SENDING UNIT KIT

J034562006-04-17

GENERAL

Kit Number

75300-05, 75298-05

Models

Kit 75298-05 fits 2002-2005 Softail^® Deuce motorcycles with Electronic Fuel Injection (EFI).

Kit 75300-05 fits all other 2002-2005 EFI Softail model motorcycles.

Additional Parts Required

The following items must also be replaced when performing this installation:

For EFI Deuce: Top plate (canopy) gasket, part number 61315-02
For All EFI Softails (Except Deuce): Top plate (canopy) gasket, part number 61381-02
(10) Screws, self-sealing, Torx^®, part number 1311D
Cable strap, part number 10065

WARNING

Rider and passenger safety depend 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. (00333b)

NOTE

This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.

Kit Contents

See Figure 7 and Table 1.

REMOVAL

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

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.

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)

See the FUEL PUMP/FUEL GAUGE SENDING UNIT section of the appropriate Service Manual. Drain the fuel tank, then remove the top plate (canopy) and the attached fuel-level sending unit.

WARNING

Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a)

In a well-ventilated area, use an evaporative solvent such as a brake cleaner, and compressed air to thoroughly clean the top plate and sending unit assembly.

See Figure 1 to identify the style of connector currently installed on the top plate.

a. For EARLY style connector (3): See Figure 2. Disconnect the ground wire (1) from the spade terminal (4) on the connector clip.

b. Cut the three wires (2) coming from the sending unit at the 3-way header (canopy connector, item 3).

c. For LATER style connector (1): See Figure 2. Disconnect the ground wire (1) from the spade terminal (4) on the connector clip.

d. See Figure 3. Remove the sending unit connector (1) from the canopy connector (2) by inserting a flat blade screwdriver into the connector to release the tab lock (3).

1	Mid-2004 and LATER-style canopy connector 72442-05 (also included in this kit)
2	Sending unit connector on mid-2004 and LATER models
3	Mid-2004 and EARLIER style canopy connector 72435-00
4	Sending unit connector on mid-2004 and EARLIER models

Figure 1. Top Plate (Canopy) Connector and Fuel-Level Sending Unit Connector Identification

1	Ground wire
2	Cut wires from earlier style connector
3	Earlier style connector with wires cut
4	Spade terminal on connector clip

Figure 2. Cutting Wires from EARLIER Style Connector (Top Plate from Similar Model Shown)

1	Later style sending unit connector
2	Later style canopy connector
3	Tab lock

Figure 3. Later Style Connector Removal (Connectors Shown Removed from Canopy)

Figure 4. Cable Strap

See Figure 4. Cut and discard the white cable strap holding the sending unit wires to the canopy arm.

If the canopy connector is the LATER style, that connector can be left in place. Discard the new connector ( Figure 7 , Item 2) provided in the kit.

See Figure 5. Remove the screw ( Figure 7 , Item D) holding the sending unit to the black fuel pump holder. Discard the sending unit but retain the screw.

Figure 5. Sending Unit Attaching Screw

INSTALLATION

1.	See Figure 7. Obtain the new fuel-level sending unit (1) from the kit.
2.	Install the new sending unit onto the black fuel pump holder so that round peg on the holder fits into the bottom hole on the new sending unit. Align the float for proper orientation. DO NOT bend the float rod.
3.	Secure with the screw (D) saved in Step 7. Tighten the screw to 25-45 in-lbs (2.8-5.1 Nm). Be sure the sending unit is tight and does not rattle.
4.	If the canopy connector WAS NOT previously removed, proceed to Step 5. If the canopy connector WAS previously removed: a. Apply a thin film of clean engine oil to the new O-ring (5) from the O-ring and clip kit (3). b. Install the O-ring in the groove of the new canopy connector (2) from the kit. c. Fit the new connector into the hole in the canopy so that the gray sleeve in the connector is on the upper side of the canopy top plate. d. At the underside of the canopy, install the new connector clip (4) from the O-ring and clip kit (3), in the same orientation to the canopy as the original clip, engaging the slots in the connector.
5.	See Figure 6. Insert the connector from the new sending unit into the bottom of the canopy connector. Guide ribs and grooves in the connector halves prevent improper installation. You should feel and hear a "click" when the connectors are mated correctly.	Figure 6. New Fuel-Level Sending Unit Connector
6.	See Figure 2. Connect the ground wire (1) to the spade terminal (4) on the connector clip.
7.	Manually cycle the float assembly through a few full cycles, from empty to full, to ensure that the float contacts function correctly.
8.	Fasten the sending unit wires to the top plate arm in the same way as the original installation with the new cable strap (C), purchased separately.
9.	Connect the fuel level sending unit connector (E) to the fuel pump.
10.	See FUEL PUMP/FUEL GAUGE SENDING UNIT: INSTALLATION in the Service Manual. Install the canopy and attached sending unit, using a new gasket (A) and ten new Torx screws (B), purchased separately.
11.	Fill the fuel tank with fuel and check for leaks.
12.	Refer to the Service Manual and follow the instructions given to re-attach the negative battery cable and install the seat.

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)

SERVICE PARTS

Figure 7. Service Parts for Fuel Level Sending Unit Kit

Table 1. Service Parts Table

Item	Description (Quantity)	Part Number
1	Fuel level sending unit	Not Sold Separately
2	Header assembly, 3-way	72442-05
3	O-ring and clip kit	72458-00
4	Clip, connector	Not Sold Separately
5	O-ring	11380
Items mentioned in text, but not included in kit:
A	Top plate gasket, EFI Softail (except Deuce) (shown)	61381-02
A	Top plate gasket, EFI Deuce (not shown)	61315-02
B	Torx screw (10)	1311D
C	Cable strap	10065
D	Stock sending unit attaching screw	1314
E	Fuel level sending unit connector to fuel pump	Not Sold Separately