Locate the existing oil pressure switch. For Dyna, Softail and FLHR models: See Figure 1. The switch (1) is located at the front of the engine cases on the left side of the oil filter mount. For XL models: See Figure 2. The switch (1) is located on the left side under the oil filter. Removal of the oil filter to access the switch will require draining the engine oil.

Remove the connector from the switch.

Remove the switch from the engine case.

See Figure 11. Wrap threads of fitting with Loctite^® High Performance Pipe Sealant with Teflon (Harley-Davidson Part Number 99818-97). For XL: Select 90° fitting (10) from kit. For Softail and 2006 and later Dyna: Select 45° fitting (11) from kit. For 2005 and earlier Dyna and FLHR: Install oil pressure sensor directly into engine case.

For Softail and 2006 and later Dyna: Install fitting and tighten to 96-144 in-lbs (10.9-16.2 Nm). Orient female port facing down for 2006 Dyna models.

Follow the instructions in the bracket kit to install the oil pressure gauge bracket.

See Figure 11. Obtain from kit, the rubber isolation gasket (7) and oil pressure gauge (8).

Fit the perimeter groove in the rubber isolation gasket to the inside edge of the bracket and the tab of the isolation gasket to the square cutout in the bracket.

Rotate the oil pressure gauge to align the face legend horizontal to the rider and push in the gauge. The tab on the gauge will align with the notch in the gasket.

See Figure 11. Route the oil pressure wire harness (13) conduit along the frame backbone and up through the upper triple clamp to the bracket.

Route the black ground lead to the ground location for the model motorcycle. Follow the instructions in the Service Manual to locate the ground terminal stud: For 2000 to 2003 XL: The wire harness ground screws can be in several locations including under the seat at the junction of the frame backbone and the extensions for the shock mounts, on the left side of the frame under the tank, or on the left side of frame near the swing arm. For 2004 and later XL: On the backside of the primary case at the rear of the engine. For 2004 and later Dyna: See Figure 4. At either of the rear ground studs (1,2) under the fuse block. For 2000 to 2003 Dyna: On top of the frame under the seat toward the tank. For 2004 and later Softail: See Figure 3. On the frame strap (1) under the seat directly in front of the battery. For 1999 to 2003 Softail: Top of the frame under the seat toward the front. For 2004 and later FLHR/I: See Figure 5. Under seat (1) directly in front of battery. For 2000 to 2003 FLHR/I: In the well underneath the seat under the circuit breaker.

Route the orange/white power lead lead underneath and down a rear frame rail to the power location for the year and model. For 2004 and later XL: Behind the left side cover, locate the orange/white power lead from the main harness to the diagnostic pin connector [91A]. For 1999 to 2003 XL: See Figure 6. A main harness orange/white power lead inside the side cover or under the seat to power the gauge.

Route the oil pressure sensor lead and connector down along the frame downtube to the oil pressure sensor.

Verify the position and length of the wire harness and the wire leads to the sensor, the power source and to the ground.

Bundle the oil pressure harness to the main wiring harness and any additional gauge harness along frame backbone by using cable straps to support wires so they do not chafe or contact hot or moving points.

Cut off the existing overmolded connector from the existing wire lead.

Plug the sealed connector on the end of the oil pressure lead onto the oil pressure sensor.

See Figure 11. Refer to the instructions for splicing under Splice Orange/White Power Lead (See Figure 10 ). Using a sealed splice (1) connector from the kit, butt splice the green and yellow wire from the harness sensor connector to the wire from the existing wire lead.

When the correct length of harness ground lead has been established, cut the lead as necessary.

If necessary, strip 3/8 inch insulation from the ground lead.

For all models except the 1999 to 2003 Dyna: See Figure 11. Crimp the 1/4 inch ring terminal (3) to the oil pressure ground wire. For 1999 to 2003 Dyna: Crimp the 5/16 inch ring terminal (2) 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 found in the Service Manual.

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

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

See Figure 9. Identify the splice configuration required.

See Figure 11. Insert the leads and crimp the metal insert of the sealed splice (1).

See Figure 11. Lubricate the oil pressure conduit (13) with soap and water and pull the wires and conduit through the housing grommet (6).

If necessary, strip 3/8 inch of wire from the ends of orange/white (power), gray/green (signal) and black (ground) wires.

Crimp the #6 ring terminal (5) to the wires.

Thread the standoff from the gauge housing kit into the bottom of the gauge and tighten.

Route wire harness around the outside of any riser covers.

Thread the ring terminated wires and conduit into the gauge housing.

Fit the grommet to the housing.

Match wire colors to terminal posts on back of oil pressure gauge:

Install a nut to secure the ring terminal over the posts and nuts on the back of the gauge.

Verify that the ring terminals or wires are not grounding against each other.

Push the gauge housing into the isolation gasket and install the flat head screw from the gauge housing kit.

Tighten the flat head screw to snug the housing up against the gasket.

Inspect the seal of isolation gasket around the perimeter of the housing.

With the wire harness along frame and to the gauge, bounce motorcycle to look for pinch points between suspension components and gauge wires.

For multiple gauges, 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.

Cable wrap wire harness or leads every foot or so along backbone and along downtube to oil pressure sensor.

Oil pressure gauge should illuminate and the oil pressure indicator light should glow red with ignition turned ON.

Start engine. At operating temperature: For all models except XL: Oil pressure gauge should read 30-38 PSI at 2000 RPM. For XL: Oil pressure gauge should read 10-17 PSI at 2500 RPM.