FUEL TANK CONSOLE KIT
J041662006-08-24
GENERAL
Kit Number
71208-07
Models
For the most up-to-date model fitment information, please see the package label or www.harley-davidson.com.
INSTALLATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the Owner's Manual and follow the instructions given to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware.
Original Equipment (O.E.) Instrument Panel Removal
| 1. | See Figure 1. Unscrew the rubber boot (6) from the odometer reset switch (5) on the left side of the O.E. instrument panel (1). NOTE When performing the following step, the carriage bolt (4) may come out when the acorn nut is removed. This is acceptable, as the bolt will be discarded. | |||||||||||||||||||||||||||||||||||||||||||||
| 2. | Remove and discard the acorn nut (2) and flat washer (3) fastening the instrument panel to the fuel tank. | |||||||||||||||||||||||||||||||||||||||||||||
| 3. | Remove and discard the TORX® head screw (8) and flat washer (9) fastening the fuel tank trim panel (7) to the rear of the fuel tank. Remove and discard the trim panel. | |||||||||||||||||||||||||||||||||||||||||||||
| 4. | Place clean shop towels on the fuel tank. Turn the instrument panel over onto the towels to expose the underside. | |||||||||||||||||||||||||||||||||||||||||||||
| 5. | If the carriage bolt (4) was not removed with the acorn nut and washer in Step 3, it can be removed from the fuel tank top plate and discarded. | 
Figure 1. Original Equipment Instrument Panel 
Figure 2. Instrument Panel Wiring | ||||||||||||||||||||||||||||||||||||||||||||
| 6. | See Figure 2. Spread the side tabs and disconnect the 12-way socket housing [39B] (1) from the speedometer connector on the underside of the console. | |||||||||||||||||||||||||||||||||||||||||||||
| 7. | Use a flat-blade screwdriver to pry between the three tabs (2) and the speedometer to raise and release the back clamp (3) from the speedometer. Remove the back clamp from the speedometer, and discard it. | |||||||||||||||||||||||||||||||||||||||||||||
| 8. | See Figure 1. Remove the odometer reset switch (5) from the hole in the side of the instrument panel. Gently push on the bottom of the speedometer (10), and remove the speedometer and gasket (11) from the instrument panel. | |||||||||||||||||||||||||||||||||||||||||||||
| 9. | Remove the speedometer gasket from the speedometer and set the speedometer aside. Discard the gasket. NOTE The indicator lamp assembly (13) can remain installed in the instrument panel. | |||||||||||||||||||||||||||||||||||||||||||||
| 10. | See Figure 2. Disconnect the eight-way pin housing [21A] (5) from the indicator lamp harness. | |||||||||||||||||||||||||||||||||||||||||||||
| 11. | Spread the side tabs and disconnect the three-way socket housing [33B] (6) from the ignition switch. | |||||||||||||||||||||||||||||||||||||||||||||
| 12. | Remove and retain the four hex head ignition switch mounting screws (7). Remove and retain the ignition switch. Discard the instrument panel. |
| 1 | Console retention nut |
| 2 | Console mount nut plate |
| 3 | Bezel screw, short (2) |
| 4 | Fuel tank top plate bracket |
Figure 3. Console Attachment To Fuel Tank Bracket
New Console Installation
| 13. | See Figure 3. Obtain the console retention nut (1), console mount nut plate (2) and two short bezel screws (3) from the kit. | |||||||||||||||||
| 14. | Slide the console retention nut into the notch in the fuel tank top-plate bracket (4). Position the nut plate to the underside of the bracket. Fasten the retention nut and nut plate in place with the two screws. Tighten the screws to 5.4–8.1 N·m (48–72 in-lbs). | |||||||||||||||||
| 15. | See Figure 5. Obtain the new chrome console (1) and console trim (6) from the kit. Starting at the rear, install the trim over the flange around the edge of the console. | |||||||||||||||||
| 16. | Obtain the new speedometer gasket (3) and the original speedometer. Install the speedometer gasket (3) over the chrome rim of the speedometer. | |||||||||||||||||
| 17. | Insert the speedometer, from the top, into the large hole in the console. Rotate the speedometer in the hole to align the face vertically for best appearance. | |||||||||||||||||
| 18. | Obtain the speedometer bezel (2) and five short bezel screws (4) from the kit. Position the bezel over the speedometer with the decorative (blind) hole in the 12 o'clock position. Using a 5/32 hex key, install one screw into the blind hole and tighten securely. Fasten the bezel to the console with the remaining four screws, leaving the 6 o'clock position open. Tighten the screws to 5.4–8.1 N·m (48–72 in-lbs). | 
Figure 4. New Console Wiring | ||||||||||||||||
| 19. | See Figure 4. Lay the console, top side down, on clean shop towels on the left-hand side of the fuel tank or a suitable work surface. | |||||||||||||||||
| 20. | Connect the three-way ignition switch socket housing [33B] to the ignition switch. Place the ignition switch into the small hole in the console. NOTE The two pins in the console will engage two of the mounting holes in the ignition switch. | |||||||||||||||||
| 21. | Obtain the new indicator lamp and harness assembly from the kit. Position the lamp mounting bracket (4) over the ignition switch. Tuck the ignition switch wires (5) into the space between the lamp mounting bracket and the left inside wall of the console, under the lamp mounting bracket. | |||||||||||||||||
| 22. | Fasten the mounting bracket and ignition switch to the console with the four hex head ignition switch mounting screws (6) removed earlier. Tighten the screws to 4–5.1 N·m (35–45 in-lbs). DO NOT OVER-TIGHTEN. | |||||||||||||||||
| 23. | Connect the socket housing (7) on the indicator lamp harness to the eight-way pin housing [21A] from the main harness. | |||||||||||||||||
| 24. | Insert the odometer reset switch, from the underside, through the hole in the side of the console, and install the rubber boot. | |||||||||||||||||
| 25. | Connect the 12-way socket housing [39B] from the main harness to the connector (8) on the back of the speedometer. | |||||||||||||||||
| 26. | Tuck the harnesses and connectors into the available space around the speedometer. See Figure 5. Remove the backing from the wire clip (12) from the kit. Affix the clip to the back of the speedometer housing as needed to aid in harness routing. | |||||||||||||||||
| WARNING Be sure wires are not pinched between console and fuel tank top plate. Pinched wires can cause short circuits and damage vehicle electrical components, which could cause loss of vehicle control resulting in death or serious injury. (00517b) | ||||||||||||||||||
| 27. | Turn the console over into the installed position. Remove the shop towels from the fuel tank. Carefully center the console assembly on the tank, lining up the mounting holes at the rear of the console and to the rear of the speedometer with the attaching holes on the tank. Ensure that wires are not pinched beneath the console, and that the vehicle harnesses exit the forward end of the console in the channels provided. | |||||||||||||||||
| 28. | Obtain the rear console screw (8) and long bezel screw (10) from the kit. a. Use a 1/8 hex key to loosely install the rear console screw into the rear tank mounting bracket. b. With a 5/32 hex key, thread the long bezel screw through the bezel and console into the console retention nut installed earlier. Do not fully tighten. c. Adjust the console to fit as snugly and as centered as possible on the fuel tank. d. Tighten the long bezel screw to 11–14 N·m (96–120 in-lbs). e. Tighten the rear console screw to 0.56–1.13 N·m (5–10 in-lbs). NOTE Ambient temperature should be at least 60° F (16° C) for proper adhesion of the ignition switch legend plate to the console. | |||||||||||||||||
| 29. | Clean the ignition switch area on the new console with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. | |||||||||||||||||
| 30. | Obtain the ignition switch legend plate (7) from the kit. Peel the liner from the adhesive backing of the legend plate. Use a tweezers to carefully position the legend plate to the cast-in depression in the console, and press firmly into place. | |||||||||||||||||
| 31. | Verify that the Ignition/Light Key Switch is turned to the OFF position. Apply a light coat of petroleum jelly or corrosion retardant material to the negative battery terminal. Refer to the Owner's Manual and follow the instructions given to re-attach the negative battery cable. | |||||||||||||||||
| 32. | Install the seat per the instructions in the Owner's 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) | ||||||||||||||||||
| 33. | Test the ignition switch, indicator lamps and speedometer for proper operation. |
SERVICE PARTS
Figure 5. Service Parts: Fuel Tank Console Kit
Table 1. Service Parts: Fuel Tank Console Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Console (instrument panel), chrome | 71758-07 |
2 | Bezel, speedometer | 71761-07 |
3 | Gasket, speedometer | 67223-00A |
4 | Screw, bezel (short) (7) | 9494 |
5 | Indicator lamp and harness assembly | 71762-07 |
6 | Trim, console | 71759-07 |
7 | Legend plate, ignition switch | 71262-05 |
8 | Screw, console (rear) | 2447 |
9 | Nut, console retention | 71784-07 |
10 | Screw, bezel (long) | 1327 |
11 | Nut plate, console mount | 71786-07 |
12 | Wire clip, adhesive-backed | 10102 |