TWO INCH OIL TEMPERATURE GAUGE FOR FLHT AND FLTR

J035412006-06-13

GENERAL

Kit Number

75265-04, 75320-05, and 75324-05

Models

Table 1. Models

Kits	Models
75265-04 Black Face	1999 and later FLHT/C/CUI and FLTR
75320-05 Metal Face	2004 and later FLHT/C/CUI and FLTR
75324-05 Silver Face	2000 and later FLHT/C/CUI and FLTR

NOTE

Silver Face Gauges (75324-04) and Metal Face Gauges (75320-04) are not compatible with Chrome Instrument Bezels.

Additional Parts Required

Proper installation of these kits will require the following special tools and materials, which are available at any Harley-Davidson dealer:

Loctite^® 565 Thread Sealant (99818-97)
Packard Crimp Tool (38125-8)
UltraTorch UT-100 (39969)

2007 and later Touring models will require the additional purchase of Oil Temperature Adapter Kit (26133-07).

2007 and later Touring models using Premium Oil Cooler Kit (26155-07):

Install Oil Cooler using instructions supplied with that kit.
Install Sensor as specified with Oil Temperature Adapter Kit.

The original hose cover will not fit, however, optional transmission interface covers can be used to conceal the hose fittings. Select from the offerings available in the Genuine Motor Accessories and Genuine Motor Parts catalog.

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.

NOTICE

It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)

WARNING

When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)

NOTE

Do not use solvent based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of plastic and rubber.

This kit requires up to 300 milliamps additional current from the electrical system.

Kit Contents

See Figure 1 and Table 1.

REMOVAL

Prepare the Motorcycle

WARNING

To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)

EFI models: Purge the fuel supply of high pressure gasoline and remove the fuel supply line. Refer to Service Manual.
Remove oil drain plug, drain engine oil, and remove oil filter. Refer to Service Manual.

Figure 1. FLHT With Outer Fairing Removed

Figure 2. FLTR With Outer Fairing Removed

Install oil drain plug.
1. Inspect O-ring for tears or damage. Replace if required. Wipe oil/debris from plug.
2. Install O-ring and drain plug. Tighten to 14-21 ft-lbs (19-28 Nm).
2007-later models: Install oil temperature adapter following the instructions in Kit 26133-07.
Clean the oil filter mount of gasket material. Lube the gasket on a new oil filter with engine oil and install the new filter. Hand-tighten oil filter 1/2 to 3/4 turn after gasket contacts filter mounting surface.

NOTE

Do not use the oil filter wrench to tighten the oil filter.

Remove Existing Equipment

1.	Remove seat and any side covers. Refer to Service Manual.
	WARNING Prevent accidental vehicle start-up, which could cause death or serious injury. First disconnect negative (-) battery cable at engine and then positive (+) cable from battery. (00280b)
2.	Remove battery according to the procedures in the Service Manual.
	WARNING Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a)
3.	Carbureted models: Turn the fuel supply valve to OFF. Remove fuel line from valve.
4.	Remove fuel tank according to the procedures in the Service Manual.
5.	FLHT/C/U: See Figure 1. Follow Service Manual instructions to remove the outer fairing/windshield from the upper fairing. FLTR: See Figure 2. Follow Service Manual instructions to remove the outer fairing from the upper fairing.
6.	Remove existing oil temperature gauge. a. Pull socket housing to release interconnect harness from the lamp and gauge. b. Remove hex nuts from studs and remove mounting bracket. c. Remove gauge from inner fairing.

INSTALLATION

Install Oil Temperature Gauge and Sending Unit

NOTE

The two inch oil temperature gauge can replace any of the four factory-installed gauges.

1.	From rider side, rotate the oil temperature gauge to align the face legend horizontal to the rider and push the gauge into the fairing.
2.	From the open front, slide mounting bracket over studs to engage tabs of bracket into inner fairing.
3.	Install two locknuts and tighten to 10-20 in-lbs (1.1-2.3 Nm).
4.	Coat sending unit with Loctite 565 Thread Sealant install sending unit into appropriate fitting.
5.	2007 and later models: Install oil temperature sensor in adapter assembly following the instructions in Kit 26133-07. Then skip to "Route Wire Harness" subtopic. NOTE The stock right side oil line cover will not be reinstalled after removal.
6.	See Figure 3. Remove the right side oil line cover between the transmission and the engine case. The supply (feed) hose is the lower line into the engine case. NOTE To gain access, both the supply (feed) and the return line can be removed. When replacing the return line, use two new hose clamps (9969).	Figure 3. Oil Hose Cover and Supply and Feed Lines
7.	See Figure 4. Fit the 90° fitting and sending unit to the supply (feed) hose. a. Cut and remove the supply (feed) clamps and discard hose. b. Using the hose from the kit, cut and fit a 1-1/4 in. (28.6 mm) segment to one end of the 90° fitting and a 1-1/4 in. (28.6 mm) segment with a worm gear clamp to the other end. c. Using worm gear clamps, install one segment on the case side with the sending unit angled up and under the return line. d. Tighten the worm gear clamps. e. If 90° fitting does not appear to line up with corresponding pipe nipple on crankcase (front), remove transmission side nipple (back), clean off threads to remove any build up of pipe fitting sealer, and install after applying Loctite 565 Thread Sealant to threads.

NOTE

When mating the fitting to the supply hose, the sending unit and clamps should always be positioned so that they do not chafe on any other components.

Figure 4. Sending Unit

Route Wire Harness

Layout the wiring harness conduit along the frame backbone and loosely locate the harness leads.
Route the three unterminated leads wrapped in conduit forward toward the gauge and bracket.
1. Route the leads along the right side of the frame backbone.
2. Thread the leads through the P-clamp.
3. FLHT: Thread the leads under the fairing cap and around the front of the steering head to the oil temperature gauge. FLTR: Thread the leads through the fairing support bracket and follow the existing wire harness to the oil temperature gauge.
See Figure 5. Locate the ground terminal and route the gauge harness black ground lead to the ground.
Route the orange/white lead from the gauge harness to the power source. 2003-earlier models: Locate an open section of orange/white power lead along the main harness. The orange/white power lead from the gauge harness will be spliced in. Refer to Service Manual. 2004-2006 models: The fuse block inside the left side cover will be fitted with an adapter to the fuse socket labeled P&A IGN to provide a gauge harness orange power lead. Refer to Service Manual. 2007-later models: The fuse block cavity marked P&A IGN is located on the right side of the vehicle. See Figure 7. The fuse block connector terminal uses the "spring tab" type connector.
2004-2006 models: See Figure 6. Route the oil temperature signal leads and connector down to the oil temperature sending unit. 2007-later models: Route the signal leads back towards the front of the vehicle and down the left frame down tube.
1. Route the signal connector and leads under the seat to the right side the battery.
2. Exit the side cover near the starter and down to the lower frame rail.
3. Route the signal leads under the transmission.
4. Push the connector and leads up behind the supply and feed lines.
1. Secure with cable straps.
2. Any excess wire harness should be coiled and secured under the fuel tank with cable straps.
Slide the segment of high temperature tubing over the connector and mate the sealed connector to the sending unit.

NOTE

Before shortening the wire harness, adjust as necessary to achieve a tight but flexible arrangement.

Bundle the oil temperature harness to the main wiring harness and any additional gauge harness under the seat with cable straps.

NOTE

The original equipment (O.E.) cover will not fit the final installation and can be left off the final installation. Accessory covers are available through the Genuine Motor Accessories and Genuine Motor Parts catalog.

Figure 5. Ground Terminal

Figure 6. Sending Unit Connector Lead Routing

Wire the Ground

When the correct length of black ground wire has been established, cut the harness ground wire as necessary.
Strip 3/8 in. of insulation from end of the ground wire.
Crimp the 1/4 in. ring terminal to the ground wire.
Remove the ground wire fastener and add the ring terminal to the stud.
Install the ground fastener and tighten to the torque specification found in the Service Manual.

Adapt Fuse Block to Power Lead

2004-later models: Access fuse block and remove fuse block cover.

See Figure 7. Identify the unused end of the fuse black adapter. Cut the terminal off at the crimp and discard.

See Figure 8. Install the end of the adapter into the socket on the back of the fuse block marked as P&A IGN on the cover of the fuse block.

NOTE

There should be a wire connected to one side of this socket on the back of the fuse block, but no wire exiting the socket and no fuse in the fuse holder on the front of the fuse block.

1	2004-2006 models
2	2007-later models

Figure 7. Fuse Block Adapter

Figure 8. Fuse Block Cover with P&A IGN Mark

Install the 2-Amp fuse in the P&A IGN slot.

Splice Orange/White Power Lead

When the correct length of orange/white power lead from the gauge harness to the ignition lead or fuse block adapter lead has been established, cut the lead.

Strip 3/8 in. of insulation from ends of the orange/white leads (including if required, the fuse block adapter lead).

See Figure 8. Identify the splice configuration (1 into 1, or 2 into 1) required for the power and signal leads for oil temperature gauge and an additional accessory.

NOTE

See Figure 9. Configuration 2 will be used when splicing one orange/white power lead into the ignition lead or when splicing orange/white leads for oil temperature gauge and an additional accessory.

1	1 into 1 Splice
2	2 into 1 Splice

Figure 9. Splice Configurations

Insert the lead(s) and crimp the metal insert of the butt splice.

NOTE

See Figure 10. Gently hold the butt butt splice from the kit in the "blue" jaws of the Packard Crimp Tool (38125-8). Feed the stripped lead(s) up to the wire stop inside the metal insert in one half of the connector. Squeeze the tool to crimp the metal insert. The tool automatically opens when finished. Repeat for the other end of the connector to capture one or two stripped leads including, if required, the fuse block adapter.

Figure 10. Splice 1 into 1 Sequence

WARNING

Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)

Avoid directing the heat toward any fuel system component. Extreme heat can cause fuel ignition/ explosion resulting in death or serious injury.
Avoid directing heat toward any electrical system component other than the connectors on which heat-shrink work is being performed.
Always keep hands away from tool tip area and heat shrink attachment.

Using the UltraTorch UT-100 (39969) or other suitable radiant heating device, heat the crimped splice from the center of the crimp out to each end until the sealant exudes out both ends of the connector and the tubing assumes a smooth cylindrical appearance.

Connect Harness to Oil Temperature Gauge

NOTE

Before stripping or crimping the ring terminals on to the gauge wire leads, inspect steering clearance, suspension clearance, and look for any pinch points along wire path. Turn forks lock to lock as part of inspection.

Strip 3/8 in. of wire from the ends of wire leads to the gauge.
Crimp #6 ring terminals (3) to leads.
See Figure 11. Match wire colors to terminal posts on back of oil temperature gauge:
1. Orange/white (power) to positive (POS) terminal.
2. Black (ground) to negative (GND) terminal.
3. Yellow (signal) to signal (SIG) terminal.
Install a nut to secure the ring terminals over the posts on the back of the gauge.

1	Black to GND
2	Orange/white to POS
3	Yellow to SIG

Figure 11. Gauge Back (Upper) and Face (Lower)

Inspect Wiring

With the wire harness along frame and to the gauge, bounce motorcycle to look for pinch points between suspension components and gauge wires.
Verify that the ring terminals or wires are not grounding against each other and cable wrap the gauge harness wires together at the back of the gauge housings.
To look for pinch points in the steering, turn front forks lock to lock.
Verify absence of pinch points or clearance from heat sources along wiring harness.

Final Assembly

1.	FLHT/C/U: Follow Service Manual instructions to install the outer fairing/windshield to the upper fairing. FLTR: Follow Service Manual instructions to install the outer fairing to the upper fairing.
2.	2004-later models: Install the fuse block.
3.	Install headlamp according to the procedures in the Service Manual.
4.	Replace fuel tank, and attach fuel line or fittings. See Service Manual.
	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)
5.	Install battery and connect the battery cables, positive (+) cable first. See Service Manual.
	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)
6.	Install seat and side covers according to the procedures in the Service Manual.
7.	Align headlamp according to instructions in the Owner's Manual.
8.	Check and, if necessary, add oil. See Owner's Manual.

Test Oil Temperature Gauge

To test oil temperature gauge, turn ignition to ON. Gauge should illuminate and read ambient temperature or remain pegged at the lowest graduation.
Start engine. With engine running, oil temperature should rise as engine warms and should read approximately 230° F at operating temperature.

SERVICE PARTS

Figure 12. Service Parts: Two Inch Oil Temperature Gauge for FLHT and FLHR

Table 2. Service Parts: Two Inch Oil Temperature Gauge for FLHT and FLHR

Item	Description (Quantity)	Part Number
1	Butt splice, 14-16 gauge (2)	70586-93
2	Ring terminal 1/4 in.	9858
3	Ring terminal #6 (3)	9856
4	Oil temperature gauge, black face	75266-04
	Oil temperature gauge, silver face	75325-05
	Oil temperature gauge, aluminum face	75321-05
5	Bracket	74655-05
6	Fuse block adapter	70329-04
7	Wiring harness	70285-04
8	Worm gear clamp #8 (4)	9969
9	Cable strap (10)	10006
10	Oil supply hose	63611-00
11	90° fitting	26409-04
12	High temperature conduit	47590ZZ
13	Sending unit	72357-04
14	Fuse 2 Amp	54305-98
15	Locknut #8-32, nylon insert (2)	7864
16	Keps nut #6-32 (3)	Not Sold Separately
Note: Items 8, 10, 11, 12 are not used on 2007 and later models.