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BILLET LED FUEL GAUGE KIT, THE SKULL COLLECTION
J039312006-04-01
GENERAL
Kit Number
75095-05
Models
  • 2004 and later FXDL/I (Dyna® Low Rider®), FXDB, FXDWG/I (Wide Glide®) and 2007 FXDC models,
  • 2004 and later carbureted or fuel-injected Softail® models,
  • 2001-2003 fuel-injected Softail models except Deuce™,
  • 2003 and later carbureted FLHR (Road King®) or FLHRS (Road King® Custom) models,
  • 2001 and later fuel-injected FLHRI (Road King®), FLHRCI (Road King® Classic) or FLHRSI (Road King® Custom) models.
NOTE
The instrument-panel mounted OE low-fuel warning lamp function will be disabled when installing this kit.
Additional Parts Required
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 available from a Harley-Davidson Dealer.
Kit Contents
See Figure 3 and Table 1.
INSTALLATION
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 Owner's 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)
Analog Fuel Gauge Removal
NOTE
The fuel gauge wires are routed through a tube in the fuel tank, and are secured by a clip at the bottom of the tank and, on some models, a clamp on the frame. Open the clip and clamp as needed, and be sure there is enough slack in the wires to be able to lift out the gauge.
  1. At the bottom left side of the fuel tank, bend back the flexible clip slightly to free the fuel gauge conduit. Open the harness clamp on the frame if necessary to free the conduit. Gently pull on the conduit to draw the Multilock connector [117] out of the tunnel.
  2. See Figure 3. Depress the pin on the socket terminal side of the connector, and pull apart the pin and socket halves.
  3. Use a pick (Snap-On TT600-3) to remove the terminals, or clip off the wires.
  4. For Carbureted Models: See Figure 3. Remove the fuel gauge by firmly grasping and carefully pulling up (Do not twist) just far enough to free the gauge from the fuel tank. Disconnect the two sending unit connectors. Feed the conduit and two wires up through the tube while removing the gauge. Remove and discard the fuel gauge. For Fuel-Injected Models: See Figure 3. Remove the fuel gauge by firmly grasping and carefully pulling up (Do not twist) on the gauge to free it from the fuel tank. Feed the conduit and three wires up through the tube while removing the gauge. Remove and discard the fuel gauge.
LED Gauge Installation
1. See Figure 3. Assemble the new O-ring (2) to the LED fuel gauge (1) from the kit.
1Orange wire to "12V O"
2Gray wire to "3V GR"
3Black wire to "GND BK"
4Yellow/white wire to "Y/W"
Figure 1. Wire Connections
2. Obtain the wiring harness from the kit. See Figure 1. Fasten the Orange wire (1) ring terminal to the gauge connection marked "12V" and "O" with one of the Phillips-head screws and star washers.
3. Fasten the Black wire (3) ring terminal to the connection point marked "GND" and "BK", and the Yellow/ White wire (4) ring terminal to the connection marked "Y/W".
4. For 2001-2003 fuel-injected models, the Gray wire (2) will not be used. Cut the wire short and tape over the end with electrical tape. The Phillips-head screw can be installed back into the hole marked "3V" and "GR". For 2004 and later carbureted models, the Gray wire (2) will not be used. Cut the wire short and tape over the end with electrical tape. The Phillips-head screw can be installed back into the hole marked "3V" and "GR". For 2004 and later fuel-injected models, fasten the Gray wire (2) ring terminal to the gauge connection marked "3V" and "GR". For ALL models: Tighten all four Phillips-head screws to 0.4–0.9 N·m (4–7 in-lbs).
5. While carefully lowering the fuel gauge, feed the wire harness down into the drain tube until the long Gray wire (B) and three short (Orange, Black, Yellow/White) wires exit the hole at the bottom of the fuel tank. Gently pull the wires (to remove slack) while installing the gauge to the fuel tank. Do not twist the gauge during installation. Hold the gauge firmly and press downward until it snaps into place.
NOTE
DO NOT attempt to connect the Gray wire socket terminal into the 4-place pin housing.
1Cavity 1: Orange
2Cavity 2: Yellow/white
3Cavity 3: Gray
4Cavity 4: Black
5Four-pin connector
Figure 2. Four-Pin Connector (viewed from wire end)
6. See Figure 2 and Figure 3. Install the wires with pin terminals (C) into the correct cavities of the 4-place pin housing (4) from the kit. See the chart below and the AMP MULTILOCK ELECTRICAL CONNECTORS, INSTALLING SOCKET/PIN TERMINALS section in the Service Manual.
  • Cavity 1: Orange
  • Cavity 2: Yellow/White
  • Cavity 3: Gray
  • Cavity 4: Black
  1. At the bottom left side of the fuel tank, mate the completed pin housing to the socket housing [117B] disconnected in Step 3. Feed the connector into the tunnel, capturing the conduit in the flexible clip at the bottom of the tank and the clamp on the frame (if so equipped).
  2. The OE gauge harness did not have the Gray wire (with socket terminal) that is included in the kit wiring harness:
  • For 2001-2003 fuel-injected models, the Gray wire will not be used. Cut the wire short and tape over the end with electrical tape.
  • For 2004 and later carbureted models, the Gray wire will not be used. Cut the wire short and tape over the end with electrical tape.
  • For 2004 and later fuel-injected models, the Gray wire will replace the Yellow/White wire found in cavity 9 of the speedometer connector [39B] (Touring or Softail models) or instrument assembly connector [20] (Dyna) later in the installation (see Step 15).
  1. Connect the long Gray wire in the following manner:
    1. Install the Gray wire into Cavity 3 of the fuel gauge socket housing [117B] on the motorcycle main harness.
    2. Route the Gray wire through the tunnel under the fuel tank, then up the front of the tank.
    3. Follow the instructions in the Service Manual to gain access to the speedometer connector [39B] (Touring or Softail) or instrument connector [20] (Dyna).
    4. Locate the Yellow/White wire in Cavity 9 of the connector, and remove the wire and terminal from the connector. Refer to the PACKARD ELECTRICAL CONNECTORS section in the Service Manual. Following removal, either cut the Yellow/ White wire short and tape over the end with electrical tape, or fold the wire back on itself and tape over the end.
    5. Route the Gray wire to the connector and install into the now-empty Cavity 9. Re-install the rear cover of the speedometer or instrument assembly connector as required. See the Service Manual.
    6. Install tape or wire ties along the path of the gray wire to secure it. Proceed to Step 16.
  2. At the bottom left side of the fuel tank, mate the completed pin connector to the socket housing [117B] previously disconnected. Feed the connector into the tunnel, capturing the conduit in the flexible clip at the bottom of the fuel tank and the clamp on the frame (if so equipped).
  3. Connect battery cables, negative (-) cable first.
  4. Refer to the Owner's 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)
NOTE
If the fuel gauge does not indicate the proper fuel level after installing this kit, check the connectors, then follow the troubleshooting procedures in the Service Manual.
SERVICE PARTS
Figure 3. Service Parts: Skull LED Fuel Gauge Kit
Table 1. Service Parts: Skull LED Fuel Gauge Kit
Item
Description (Quantity)
Part Number
1
Fuel gauge, LED Skull
Not Sold Separately
2
O-ring, fuel gauge
27730-04
3
Wiring harness
70026-05
4
Pin housing, 4-way
72904-01BK
5
Hardware Kit (Service only - contains items 6 and 7)
75003-04
6
Phillps-head screw (4)
Not Sold Separately
7
Star washer (4)
Not Sold Separately
Items mentioned in text:
A
Gray wire extension
B
Wire conduit
C
Pin terminals