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Mini-Tach Gauge Kit
J031182006-08-31
GENERAL
Kit Number
67201-04A, 68031-05
Models
When installed with a mini-tach bracket kit corresponding to year and model and a gauge housing kit, this mini-tach fits 2004 and later Softail®, FDXWG and FLHR model motorcycles.
Additional Parts Required
A gauge housing kit, and a mini-tach bracket kit that fits the specific year and model motorcycle are required for proper installation of this kit.
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.
Special tools, and additional parts or supplies will also be needed. See a Harley-Davidson Dealer for further information.
Electrical Overload
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)
The mini-tach with shift light requires up to 280 milliamps additional current from the electrical system.
Kit Contents
See Figure 7 and Table 1.
INSTALLATION
Preparation
For EFI models:
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)
Follow the instructions found in the Service Manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line.
For ALL models, WITH maxi-fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse.
For ALL models, WITHOUT maxi-fuse:
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 negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
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)
2. For carbureted models: Turn the fuel supply valve to OFF. Remove the fuel line from the valve.
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)
3. For ALL models: Follow the instructions in the Service Manual to remove the instrument console from the fuel tank.
4. See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank.
5. For all models EXCEPT FLHR or 1986 and later FL Softail models with Chrome Headlight Nacelle Kit (Part Number 67907-96): Follow the instructions in the Service Manual to remove the headlamp housing. For FLHR models, or Softail models WITH the Nacelle Kit: Follow the instructions in the Service Manual and the mini-tach bracket kit (purchased separately) to remove the handlebar shroud.
Mini-Tach Bracket Installation
  1. For all models except FLHR: Install the mini-tach bracket components per the instructions in that kit. For FLHR models: Follow the instructions in the Service Manual and the mini-tach bracket kit to install the handlebar shroud and bracket components.
  2. See Figure 7. Select the rubber isolation gasket (1) from this kit.
    3. NOTE
    Lubricating the gasket with soap and water will make installation of the gasket easier.
    The attached grommet will be oriented toward the bottom of the gasket.
  3. Fit the perimeter groove in the rubber isolation gasket to the inside edge of the bracket and the grommet tab (A) of the isolation gasket to the square cutout in the bracket.
HARNESS ROUTING AND CONNECTION
NOTE
Kit 69829-06 (black face gauge) contains ring terminals and wire leads (see Figure 7 and Table 1 ) that allow installation on certain models that were manufactured only with black face gauges.
Kits 69827-06 (Nostalgic face) and 69828-06 (Spun Aluminum face) do not contain these additional items. Installation of a Nostalgic- or Spun Aluminum-face kit on these vehicles may require separate purchase of one or more of these items. See a Harley-Davidson Dealer for further information.
  1. Obtain the mini-tach wire harness (2) from the kit, and route as follows:
    1. Route the three unterminated leads (B) of the mini-tach wire harness through the front forks and upper fork bracket (triple clamp) toward the mini-tach bracket.
    2. Route the terminated end (C) of the harness back along the frame backbone toward the seat. Follow existing wiring where practical.
Connect the Black Lead to the Vehicle Ground
Butt splicing is a necessary step in the installation of the mini-tach to the motorcycle. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual for proper butt splicing procedures.
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 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.
  1. For all models EXCEPT 1996 through 2003 XL: Locate the main harness chassis ground connection on the frame. See the Service Manual for your model and year vehicle for specific location. For 1996 through 2003 XL models: See the SEALED BUTT CONNECTOR and WIRING DIAGRAM sections of the Service Manual. Use a butt-splice (6) from the kit to splice the Black lead from the mini-tach harness to one of the Black (BK) wire leads coming from the instrument cluster connector [20].
    1. Remove the ground screw or nut from the chassis ground.
    2. Select the appropriate ring terminal (3 or 4) to fit the ground screw or stud.
    3. Cut the Black wire on the mini-tach wire harness to easily reach the ground location, and crimp the ring terminal to the end of the wire according to the PACKARD crimping tool instructions in the Service Manual.
    4. Install the ring terminal to the ground connection, and secure per the torque specification in the Service Manual.
  2. Determine if there is sufficient slack in the lead so that handlebar movement will not be restricted.
Connect the Pink Lead to the Signal Source
6. Use the Service Manual wiring diagrams to locate the tachometer signal source for your model and year vehicle. For 1984-1999 Softail and 1996-1998 FXDWG models: The tachometer signal source is the coil primary terminal with the Pink (PK) or Blue (BE) wire lead attached. For 1999-2003 FXDWG and 2000-2003 Softail models: The tachometer signal source is the Pink (PK) wire either tucked inside or terminated and cable-strapped to the conduit at the speedometer connector [39B] mounted inside the fuel tank console. For 1994-1998 FLHR models: The tachometer signal source is the ignition or ECM harness connector [8] under the right side cover. For 1999-2003 FLHR models: The tachometer signal source is the Pink (PK) wire near the speedometer connector [39B], either tucked underneath the conduit, or terminated with a single connector and cable-strapped to the outside of the conduit. For 1996-2003 XL Custom models: See Figure 4. The tachometer signal source is the #7 cavity of the instrument lights connector [20]. The connector is located under the fuel tank or in the handlebar riser cover on XL Custom models. For all other models: The tachometer signal source is the #3 cavity in the connector [39B] on the back of the speedometer. See Figure 5. Follow the PACKARD ELECTRICAL CONNECTOR: MICRO 64 instructions in the Service Manual. Insert the socket terminal on the Pink (PK) mini-tach wire harness signal lead into cavity #3 of connector [39B].
a. Cut off and discard the terminal on the Pink (PK) mini-tach wire harness signal lead.
b. Select the appropriate ring terminal from the kit to fit the coil stud diameter.
c. Crimp the ring terminal to the end of the wire according to the PACKARD crimping tool instructions in the Service Manual.
d. Remove the nut from the coil primary terminal with the Pink (PK) or Blue (BE) wire attached. Place the ring terminal from the Pink (PK) mini-tach lead to the coil terminal, and tighten the nut to 0.4–0.9 N·m (4–7 in-lbs).
e. Cut off and discard the terminal on the Pink (PK) mini-tach wire harness signal lead.
f. Obtain the signal adapter wire lead (12) and a butt-splice connector (6) from the kit. See Figure 1. Cut the Multilock socket terminal from the signal adapter wire lead, close to that terminal. Splice the signal adapter wire lead to the mini-tach wire harness signal lead according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
g. Free the Pink (PK) tachometer signal source wire inside the fuel tank console, and connect the signal adapter wire lead to the tachometer signal source wire.
h. Cut off and discard the terminal on the Pink (PK) mini-tach wire harness signal lead.
i. Remove the Pink (PK) lead from the ignition or ECM harness connector cavity #3 according to the DEUTSCH ELECTRICAL CONNECTOR instructions in the Service Manual. Cut the lead about one inch (25.4 mm) from the terminal.
j. Obtain a butt-splice connector (6) from the kit. See Figure 2 , the 2 into 1 splice configuration. Splice the mini-tach wire harness signal lead and two segments of the Pink (PK) lead from cavity #3 according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
k. Re-insert the terminal and Pink (PK) lead into cavity #3 according to the DEUTSCH ELECTRICAL CONNECTOR instructions in the Service Manual.
l. Cut off and discard the terminal on the Pink (PK) mini-tach wire harness signal lead.
m. Obtain the signal adapter wire lead (12) and a butt-splice connector (6) from the kit. See Figure 3. Cut the Deutsch socket terminal from the signal adapter wire lead, close to that terminal. Splice the signal adapter wire lead to the mini-tach wire harness signal lead according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
n. Free the Pink (PK) tachometer signal source wire from the conduit on the vehicle, and connect the signal adapter wire lead to the tachometer signal source wire.
o. Cut off and discard the terminal on the Pink (PK) mini-tach wire harness signal lead.
p. Obtain the signal adapter wire lead (12) and a butt-splice connector (6) from the kit. Note: Most 1996-1998 models will have an AMP Multilock connector in this position, while most 1999-2003 models will have a Deutsch connector. Verify connector type before proceeding. See Figure 1 and Figure 3. Cut the un-needed socket terminal from the signal adapter wire lead, close to that terminal. Splice the signal adapter wire lead to the mini-tach wire harness signal lead according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
q. Follow the AMP MULTILOCK ELECTRICAL CONNECTOR or DEUTSCH ELECTRICAL CONNECTOR instructions in the Service Manual. Insert the signal adapter wire lead terminal into cavity #7 of instrument lights socket housing [20B].
7. Determine if there is sufficient slack in the lead so that handlebar movement will not be restricted.
1Deutsch socket terminal
2Multilock socket terminal (discard)
Figure 1. Cut Multilock Terminal From Adapter Lead
11 into 1 splice
22 into 1 splice
33 into 1 splice
Figure 2. Splice Configurations
1Deutsch socket terminal (discard)
2Multilock socket terminal
Figure 3. Cut Deutsch Terminal From Adapter Lead
1Instrument connector #7 cavity
Figure 4. Instrument Lights Connector [20] (2003 XL Custom shown)
Figure 5. Speedometer Connector [39] (2004 FXST shown)
Connect the Orange/ White Lead to the Power Source
8. Use the Service Manual wiring diagrams to locate the tachometer power source for your model and year vehicle. For 1984-1995 Softail models: The tachometer power source is the 15 Amp accessory circuit breaker with two Orange/ White leads inside the fuel tank console. For 1996-2003 Softail and FXDWG models: The tachometer power source is the #2 cavity in the tail lamp connector [7] under the seat. For 2004 and later Softail models: The tachometer power source is an open fuse position on the fuse panel. See the Wiring Diagram for your model and the FUSES section of the Service Manual. For 2004 and later FXDWG models: The tachometer power source is an open fuse position on the electrical caddy. See the Wiring Diagram for your model and the ELECTRICAL CADDY section of the Service Manual. For 1994-2003 FLHR models: The tachometer power source is an orange/ white (O/W) main harness power lead inside the right side cover, near the top. For 2004 through 2006 FLHR models: The tachometer power source is an open fuse position on the fuse panel. See the Wiring Diagram for your model and the SYSTEM FUSES section of the Service Manual. For 2007 and later FLHR models: The tachometer power source is an open fuse position on the fuse panel. See the Wiring Diagram for your model and the SYSTEM FUSES section of the Service Manual. For 1996-2003 XL Custom models: See Figure 6. The tachometer power source is an Orange/ White (O/W) main harness power lead inside the side cover or under the seat. For 2007 and later XL Custom models: The tachometer power source is an open fuse position on the fuse panel. See the Wiring Diagram for your model and the SYSTEM FUSES section of the Service Manual.
a. Cut off and discard the terminal on the Orange/ White (O/W) mini-tach wire harness power lead.
b. Select the appropriate ring terminal from the kit to fit the circuit breaker stud diameter.
c. Crimp the ring terminal to the end of the wire according to the PACKARD crimping tool instructions in the Service Manual.
d. Remove the nut from the circuit breaker terminal with two Orange/ White (O/W) wires attached. Place the ring terminal from the Orange/ White (O/W) mini-tach lead to the circuit breaker terminal, and tighten the nut securely.
e. Cut off and discard the terminal on the Orange/ White (O/W) mini-tach wire harness power lead.
f. Remove the Orange/ White (O/W) lead from the tail lamp pin housing [7A] cavity #2 according to the AMP MULTILOCK ELECTRICAL CONNECTOR instructions in the Service Manual. Cut the lead about one inch (25.4 mm) from the terminal.
g. Obtain a butt-splice connector (6) from the kit. See Figure 2 , the 2 into 1 splice configuration. Splice the mini-tach wire harness power lead and two segments of the Orange/ White (O/W) lead from cavity #2 according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
h. Re-insert the terminal and Orange/ White (O/W) lead into cavity #2 according to the AMP MULTILOCK ELECTRICAL CONNECTOR instructions in the Service Manual.
i. Remove the fuse block cover. Remove the two hex head screws fastening the fuse block bracket, and pull the bracket and fuse block assembly away from the motorcycle frame.
j. Depress the tab retaining the left-hand fuse block, and slide the block out of the mounting slots.
k. Locate the fuse cavity indicated as "P&A IGN" on the fuse block cover. There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Insert the terminal on the Orange/ White wire of the mini-tach wire harness until it stops. Refer to a nearby factory-installed terminal for comparison to ensure proper orientation and depth.
l. See Figure 7. Install the 2 Amp fuse (8) from the kit into the P&A IGN fuse cavity to complete the circuit.
m. Slide the fuse block into the mounting slots in the fuse block bracket until it clicks firmly into place. Place the bracket and fuse block assembly into position, and fasten with the two hex head screws removed earlier. Tighten securely. Re-install the fuse block cover.
n. Remove the electrical caddy from the vehicle per the Service Manual instructions.
o. Locate the fuse cavity indicated as "OPEN" on the electrical caddy. There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Insert the terminal on the Orange/ White wire of the mini-tach wire harness until it stops. Refer to a nearby factory-installed terminal for comparison to ensure proper orientation and depth.
p. See Figure 7. Install the 2 Amp fuse (8) from the kit into the OPEN fuse cavity to complete the circuit.
q. Re-install the electrical caddy and cover onto the vehicle per the instructions in the ELECTRICAL CADDY section of the Service Manual.
r. Cut off and discard the terminal on the Orange/ White (O/W) mini-tach wire harness power lead.
s. Obtain a butt-splice connector (6) from the kit. Carefully slice open an area of the main harness wrap, and cut an Orange/ White (O/W) main harness power lead at an accessible point. Splice the mini-tach wire harness power lead to the main harness power lead according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
t. Remove the left-hand side cover, fuse block and dust cover per the instructions in the Service Manual.
u. Locate the fuse cavity indicated as "P&A IGN" "2A MAX". There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Remove the three existing fuses in this row, noting their location.
v. Gently remove the orange plastic secondary lock from the fuse block.
w. See Figure 7. Obtain the Orange/ White power adapter wire (7) from the kit. Insert the terminal on the adapter wire into the "P&A IGN" "2A MAX" cavity until it stops. Refer to a nearby factory-installed terminal for comparison to ensure proper orientation and depth. Re-install the secondary lock.
x. Cut the excess length from the Orange/ White wire of the mini-tach wire harness to within easy reach of the Orange/ White adapter wire installed in Step 6d.
y. Using a butt-splice connector (6) from the kit, splice the two Orange/ White wires.
z. Install the 2 Amp fuse (8) from the kit into the P&A IGN fuse cavity to complete the circuit. Re-install the three fuses removed in Step b (above) into the proper cavities.
aa. Install the dust cover onto the fuse block, and install the fuse block per the instructions in the Service Manual.
ab. Remove the right-hand side cover, fuse block and dust cover per the instructions in the Service Manual.
ac. Locate the fuse cavity indicated as "P&A IGN" "2A MAX". There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Remove the three existing fuses in this row, noting their location.
ad. Gently remove the orange plastic secondary lock from the fuse block. Insert the terminal on the Orange/ White wire of the mini-tach wire harness until it stops. Refer to a nearby factory-installed terminal for comparison to ensure proper orientation and depth. Re-install the secondary lock.
ae. See Figure 7. Install the 2 Amp fuse (8) from the kit into the P&A IGN fuse cavity to complete the circuit. Re-install the three fuses removed in Step b (above) into the proper cavities.
af. Install the dust cover onto the fuse block, and install the fuse block per the instructions in the Service Manual.
ag. Cut off and discard the terminal on the Orange/ White (O/W) mini-tach wire harness power lead.
ah. Obtain a butt-splice connector (6) from the kit. Carefully slice open an area of the main harness wrap, and cut an Orange/ White (O/W) main harness power lead at an accessible point. Splice the mini-tach wire harness power lead to the main harness power lead according to the SEALED BUTT SPLICE CONNECTOR instructions in the Service Manual.
ai. Remove the left-hand side cover from the vehicle. Loosen the "H"-bracket per the instructions in the Service Manual, and pull it away from the frame to gain access to the back side of the fuse block.
aj. Locate the fuse cavity indicated as "P&A IGN" "2A MAX". There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Insert the terminal on the Orange/ White wire of the mini-tach wire harness until it stops. Refer to a nearby factory-installed terminal for comparison to ensure proper orientation and depth.
ak. See Figure 7. Install the 2 Amp fuse (8) from the kit into the P&A IGN fuse cavity to complete the circuit.
al. Re-fasten the "H"-bracket to the vehicle frame per the instructions in the Service Manual. Re-install the left-hand side cover.
1Power (O/W) lead in main harness
2Ground
Figure 6. Wire Harness and Ground Location (2003 or earlier XL)
9. ALL models: At the front of the vehicle, lubricate the mini-tach harness conduit with soapy water, and pull the three unterminated leads and conduit up through the grommet at the bottom of the isolation gasket.
10. Obtain the mini-tach (10) from the kit. Orient the face of the gauge so it reads upright, and slide the mini-tach into the bracket and isolation gasket from the front side.
11. Obtain the three small ring terminals (5) from the kit, and crimp the terminals to the mini-tach harness wire ends according to the Packard crimping tool instructions in the Service Manual.
12. Install the ring terminals to the back of the mini-tach, matching the wire colors to the proper terminal posts as follows:
a. Orange/ White (power) to post marked "+".
b. Black (ground) to post marked "G".
c. Pink (signal) to post marked "S".
NOTE
Over-tightening the nuts may damage the mini-tach.
13. Use the nut and lock washer on each post to secure the ring terminal to that post. Tighten the nuts to 0.4–0.9 N·m (4–7 in-lbs). Verify that the ring terminals or wire leads are not grounding against each other.
14. Use cable straps (9) from the kit to secure the mini-tach wire harness to the vehicle harnesses.
FINAL ASSEMBLY
NOTE
During re-assembly, check the wire harness along its entire length for clearance from moving parts, heat sources, sharp edges and pinch points.
Flex the front suspension, and turn the front forks to the full left and right stops to check for smooth and free operation and pulling or binding of the harness.
1. For all models except FLHR: Follow the instructions in the Service Manual to re-install the headlamp housing. For FLHR models: Follow the instructions in the Service Manual to re-install the handlebar shroud.
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)
2. Install the fuel tank. Refer to FUEL TANK, INSTALLATION (Carbureted or EFI Engine) in the Service Manual.
3. Refer to the Service Manual, and follow the instructions given to re-install the seat.
4. Connect the negative (-) battery cable.
5. Install the maxi-fuse.
NOTE
Refer to the OPERATING RECOMMENDATIONS in the Owner's manual for the maximum recommended engine speed for your model.
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)
NOTICE
Do not run the engine at extremely high RPM with clutch disengaged or transmission in neutral. Running an engine at high RPM can result in engine damage. (00177a)
6. Turn the Ignition/ Light Key Switch to ON, and start the motorcycle.
a. With engine idling, the mini-tach should indicate idle RPM (950 to 1150 RPM).
b. The mini-tach should respond to changes in the throttle settings.
SERVICE PARTS
Figure 7. Service Parts, Mini-Tach Gauge Kit
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Common items
for ALL kits
1
Gasket, mini-tach isolation
67952-96
2
Wire harness, mini-tach
67245-04A
3
Ring terminal, #18-22 AWG (1/4 in. stud)
9858
4
Ring terminal, #18-22 AWG (5/16 in. stud)
9859
5
Ring terminal, #18-22 AWG (#6 stud) (3)
9856
6
Butt-splice connector, #18-20 AWG (red)
70585-93
7
Wire lead, power adapter, 4 in. (102 mm) long, (Orange/ White)
67969-04
8
Fuse, blade type, 2A
54305-98
9
Wire tie (6)
10006
Kit 67201-04A
(Metal face)
additional contents
10
Gauge, mini-tach
Not sold separately
Kit 68031-05
(Nostalgic face)
additional contents
10
Gauge, mini-tach
Not sold separately
11
Ring terminal, #18-22 AWG (#10 stud) (3)
9857
12
Wire lead, signal adapter, 24 in. (0.6 m) long (Pink)
70231-04
13
Wire lead, signal extension, 32 in. (0.8 m) long (Pink)
70230-04
Items mentioned in text, but not included in kits:
A
Grommet tab on isolation gasket
B
Unterminated end of mini-tach wire harness
C
Terminated end of mini-tach wire harness