FLUSH-MOUNT LED FUEL GAUGE AND GAS CAP KIT
J039332009-08-18
GENERAL
Kit Number
62823-06A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
WARNINGRider 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.
INSTALLATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
WARNINGWhen 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)
NOTE
Extended exposure of gas cap to a wet environment (rain/washing) may cause a small amount of water to collect between the pop-up housing and the threaded body. Simply remove the gas cap and tilt to drain. Water cannot flow through the gas cap.
Install Flush-Mount Gas Cap and Chrome Trim Ring
| 1. | Remove stock gas cap from fuel tank. | |
| 2. | Clean and wipe inside surface of fuel tank filler cup, O-ring seal surface, and trim ring adhesive surface with an equal mixture of isopropyl alcohol and distilled water. | |
| 3. | See Figure 1. Install gas cap into fuel tank. | |
| 4. | Push down on gas cap and rotate clockwise one-eighth of a turn to lock. To unlock, push down on gas cap and rotate counterclockwise one-eighth of a turn. | |
| 5. | See Figure 2. Before removing adhesive backing, note position of arrow on inside diameter of chrome trim ring. |  Figure 1. Screw in Gas Cap  Figure 2. Note Position of Arrow on Trim Ring |
| 6. | See Figure 3. With the arrow pointing toward front of the motorcycle, rotate chrome trim ring slightly to determine best position of bottom chrome trim ring to contour of the fuel tank. NOTE As you rotate trim ring, you will see gaps between trim ring and fuel tank. Rotate trim ring to position that best eliminates gaps between fuel tank and trim ring. Rotation of trim ring should be minimal. |  Figure 3. Determine Position for Chrome Trim Ring |
| 7. | See Figure 4. Mark position of chrome trim ring with masking tape or grease pencil. | |
| 8. | Carefully cut masking tape with a hobby knife making sure not to scratch chrome trim ring or paint surface on fuel tank. | |
| 9. | Peel off adhesive backing from chrome trim ring. | |
| 10. | Using gas cap to center, and masking tape (or grease pencil mark) to align, press chrome trim ring firmly into position for about ten seconds. | |
| 11. | Peel off masking tape (or remove grease pencil mark) from chrome trim ring and fuel tank. NOTE Allow chrome trim ring to cure for about 5-7 minutes before you continue with kit installation. |
Install Flush-Mount LED Fuel Gauge
| 1. | Remove the seat following the instructions in the service manual. | |||||
| WARNING Disconnect negative (-) 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. (00049a) WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) | ||||||
| 2. | Disconnect battery cables, negative (-) cable first. | |||||
| 3. | Remove stock fuel gauge. Refer to service manual for instructions. | |||||
| 4. | Place three wires down tube of fuel tank from LED fuel gauge. | |||||
| 5. | See Figure 5 and Figure 6. Place LED fuel gauge in the fuel tank cup. NOTE The narrow tab on the gauge housing must align with the tabs at the front of the fuel tank cup. The wide tab on the gauge housing must align with the tabs at the rear of the fuel tank cup. | 
Figure 4. Align Trim Ring and Press into Place  Figure 5. Align Narrow Tab with Front Tabs in Fuel Tank Cup | ||||
| 6. | To open, press down on center of fuel gauge until you hear a CLICK. The center portion of the fuel gauge will pop out when released. Push wires from bottom to aid removal. | |||||
| 7. | See Figure 7 and Figure 8. Pull fuel gauge from housing. The gauge housing will be in the unlocked position. Loosen (but do not remove) screws. Put fingers on screw heads, press down on them, and rotate clockwise along the slot to the countersunk hole. | |||||
| 8. | Secure gauge housing in fuel tank by tightening four TORX® screws. | |||||
| 9. | See Figure 9. Place fuel gauge into housing and press down until you hear a CLICK to close. | |||||
| 10. | See Figure 10. Install wires into the correct cavities of the four-pin connector from the kit. Refer to Appendix B in the service manual. | |||||
| 11. | 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). | |||||
| 12. | Connect battery cables, negative (-) cable first. | |||||
| 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) | ||||||
| 13. | Install the seat following the instructions in the service manual. |
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.
Figure 6. Align Wide Tab with Rear Tabs in Fuel Tank Cup
Figure 7. Gauge Housing in Unlocked Position
Figure 8. Gauge Housing in Locked Position
Figure 9. Close Fuel Gauge
| 1 | Cavity 1: Orange |
| 2 | Cavity 2: Yellow/white |
| 3 | Cavity 3: Black |
| 4 | Four-pin connector |
Figure 10. Four-Pin Connector (viewed from wire end)
OPERATION
See Figure 11. When the gauge receives power, all the blue LEDs (1) will illuminate and will turn off one at a time until the approximate fuel level in the tank is displayed.
The fuel pump icon (2) is illuminated at all times during operation. The fuel pump icon is not a low fuel level warning light.
The photocell (3) senses ambient light level and will dim the fuel pump icon and LEDs in low light conditions.
| 1 | LED segments |
| 2 | Fuel pump icon |
| 3 | Photocell location |
Figure 11. Gauge Features
SERVICE PARTS
Figure 12. Service Parts: Flush-Mount LED Fuel Gauge and Gas Cap Kit
Table 1. Service Parts: Flush-Mount LED Fuel Gauge and Gas Cap Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
LED fuel gauge assembly (includes items 1 through 4) | Not Sold Separately | |
1 | Fuel gauge | 63029-06C |
2 | Gauge housing | 62834-06 |
3 | Wiring harness | Not Sold Separately |
4 | Pin housing, 4-place | 72904-01BK |
5 | Chrome trim ring | 63039-07 |
6 | Gas cap (includes item 7) | 62825-06A |
7 | O-ring | 11595 |