LED FUEL GAUGE KIT

J044832009-09-28

GENERAL

Kit Number

75242-08, 75051-08, 75098-08, 75231-08, 75358-10, 75345-10

Models

For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Kit Contents

See Figure 2 and Table 1.

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.

REMOVAL

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)

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

	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)
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.

Removing the Analog Fuel Gauge

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.

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.
See Figure 2. Press the pin on the socket terminal side of the connector, and pull apart the pin and socket halves.
See Appendix B in an appropriate service manual. Use a pick (Snap-On TT600-3 or equivalent) to remove the terminals or clip off the wires. Remove and discard the fuel gauge.
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.
Remove and discard the rubber gasket.

INSTALLATION

See Figure 2. Assemble the new gasket (3) to the LED fuel gauge (1) from the kit. Install the gasket so the flat side contacts the edge of the gauge.

See Figure 1. Use three of the Phillips-head screws and washers from the kit to connect the wires as follows: Fasten the Orange wire (1) ring terminal to the gauge connection marked "12V and "O" with a screw and washer. Fasten the Black wire (2) ring terminal to the connection marked "GND" and "BK" with a screw and washer. Fasten the Yellow/White wire (3) ring terminal to the connection marked "Y/W" with a screw and washer.

While carefully lowering the fuel gauge, feed the wire harness (2) down into the drain tube until the 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 down until it snaps into place.

Install the three wires with pin terminals (B) into the correct cavities of the 4-place pin housing (4) from the kit. See below and Appendix B of an appropriate service manual. - Cavity 1: Orange - Cavity 2: Yellow/White - Cavity 3: Open - Cavity 4: Black

1	Orange wire to "12V O"
2	Black wire to "GND BK"
3	Yellow/White wire to "Y/W"

Figure 1. Wire Connections

At the bottom left side of the fuel tank, mate the completed pin housing to the socket housing [117B] disconnected in Step 3 of the REMOVAL section. 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)

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)

Refer to the owner's manual and follow the instructions given to connect the negative (-) battery cable and install the seat.

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 2. Service Parts: LED Fuel Gauge Kit

Table 1. Service Parts Table: LED Fuel Gauge Kit

Item	Description (Quantity)	Part Number
1	Fuel gauge, LED	Not Sold Separately
2	Wiring harness	70008-08
3	Gasket, fuel gauge	27730-04
4	Pin housing, 4-pin	72904-01BK
5	Hardware kit (not shown)	75003-04
Items mentioned in text, but not included in kit:
A	Wire conduit
B	Pin terminals