FAIRING MOUNT TWO-INCH OIL TEMPERATURE GAUGE
J047902009-08-27
GENERAL
Kit Number
75265-04A, 75320-05A, and 75324-05A
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Table 1. Oil Temperature Gauge Kits
Kit | Description |
|---|---|
75265-04A | Black face |
75320-05A | Spun aluminum face |
75324-05A | Silver face |
Tools and Supplies Required
A Packard Crimping Tool (HD-38125-8) is required for the proper installation of this kit.
Loctite® 565 Thread Sealant (H-D Part Number 99818-97) will also be required.
These items are available from a Harley-Davidson dealer.
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 this year and model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
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)
WARNINGWhen 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)
This kit requires up to 300 mA additional current from the electrical system.
NOTE
Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of plastic and rubber.
INSTALLATION
Prepare the Motorcycle
| 1. | Follow the instructions in the service manual to: a. Remove the oil drain plug, drain the engine oil, and remove the oil filter. b. Inspect the oil drain plug O-ring for tears or damage, and replace if required. Wipe any oil or debris from the plug. Install the O-ring onto the plug. c. Install the drain plug, and tighten to 19–28 N·m (14–21 ft-lbs). d. Clean the oil filter mount of gasket material. Lube the gasket on a new oil filter with engine oil and install the new filter. Hand-tighten the oil filter until the gasket contacts the filter mounting surface, plus an additional 1/2-3/4 turn. NOTE Do not use the oil filter wrench to tighten the oil filter. | |
| 2. | Remove the right-side and left-side covers per service manual instructions. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) WARNINGDisconnect 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) | ||
| 3. | Models with main FUSE: Refer to the service manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. | |
| 4. | FLHT/C/U models: Follow the service manual instructions to remove the outer fairing/windshield from the upper fairing. FLTR models: Follow the service manual instructions to remove the outer fairing from the upper fairing. NOTE While the two-inch oil temperature gauge can replace any of the four factory-installed two-inch gauges or plugs, these instructions will assume the gauge is being mounted in the lower left location as viewed from the rider position. | |
| 5. | Models WITH air temperature gauge: Remove the air temperature gauge. Models WITHOUT air temperature gauge: Remove the plug from the lower left-side gauge opening (below the fuel gauge). a. Disconnect the three-way and two-way socket housings to release the interconnect harness from the air temperature gauge and lamp. b. Remove the hex nuts from the gauge mounting studs, and remove the mounting bracket. c. Remove the gauge from the inner fairing. |
Install the Oil Temperature Gauge
| 1. | See Figure 3. Obtain the oil temperature gauge (1) from the kit. From the rider position, rotate the gauge to align the face legend horizontal to the rider, and push the gauge into the fairing. | |
| 2. | From the front of the vehicle, slide the gauge mounting bracket (2) over the threaded gauge studs to engage the tabs of the bracket into the inner fairing. | |
| 3. | Install two locknuts (3) and tighten to 1.1–2.3 N·m (10–20 in-lbs). |
Install the Oil Temperature Sending Unit
| 1. | See Figure 1. Remove the unused pipe plug (3) (NOT the engine oil drain plug, item 2) from the left front of the oil pan. | 
Figure 1. Oil Pan and Plugs, FL Touring Models | ||||||||
| 2. | See Figure 3. Obtain the oil temperature sending unit (4) and adapter fitting (5) from the kit. Coat the clean threads of the adapter fitting with Loctite 565 Thread Sealant, and install the fitting into the pipe plug hole in the oil pan. | |||||||||
| 3. | Coat the clean threads of the sending unit with Loctite 565 Thread Sealant, and install the sending unit into the adapter fitting. |
Route the Wire Harness
| 1. | Obtain the oil temperature gauge wiring harness (6) from the kit. Plug the two-way connector on one end of the harness into the mating connector on the oil temperature sensor. | |||||||
| 2. | Route the harness: a. to the right side frame tube. b. Follow the rear brake line routing to the brake side foot control. c. Secure the wire harness to the frame tubes with cable straps (8) from the kit. NOTE DO NOT secure the harness to the brake line. | |||||||
| 3. | Continue the wire harness up the right-side frame tube, and through the P-clamp located near the steering head. Follow the vehicle harness into the fairing, and across to the left side where the oil temperature gauge is located. | |||||||
| 4. | Locate the air temperature gauge two-way positive lock terminal housing [114B] and cut the terminals and housing from the orange and black wires. | |||||||
| 5. | Use the Packard Crimping Tool (HD-38125-8) to strip approximately 3/8-inch (9.5 mm) of insulation from the wires of circuit [114], and crimp a #6 ring terminal (7) from the kit onto the end of each wire. | |||||||
| 6. | Strip approximately 3/8-inch (9.5 mm) of insulation from the unterminated yellow and black wires of the oil temperature gauge wiring harness, and crimp a #6 ring terminal onto the end of each wire. | |||||||
| 7. | Remove the three hex nuts with lockwashers (A) from the terminal posts on the back of the gauge. Install the wire harness ring terminals to the posts as shown in Figure 2. Fasten the ring terminals with the nuts, and tighten securely a. Two black wire terminals to the GND post. b. Orange wire terminal to the POS post. c. Yellow wire terminal to the SIG post. | 
Figure 2. Gauge Back (Upper) and Face (Lower) | ||||||
| 8. | Check along the path of the oil temperature gauge wiring harness for: Use a cable strap from the kit to bind the gauge harness wires together at the back of the gauge. Use a cable strap to bind the air temperature gauge three-way spade terminal housing [115B] to the interconnect harness. a. Pinch points between suspension components and the harness. b. Clearance from heat sources along the harness c. Pinch points in the steering (turn the front forks from lock to lock). d. Ring terminals or wires grounding against each other. |
RETURN TO SERVICE
| 1. | FLHT/C/U models: Follow the service manual instructions to install the outer fairing/windshield to the upper fairing. FLTR models: Follow the service manual instructions to install the outer fairing to the upper fairing. | |
| 2. | Install the headlamp according to the procedures in the service manual. | |
| 3. | Verify that the ignition/key switch is turned to the OFF position. Models with main FUSE: Refer to the service manual and follow the instructions given to install the main fuse. Models with main CIRCUIT BREAKER: Apply a light coat of Harley-Davidson electrical contact lubricant (Part Number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Refer to the owner's/service manual and follow the instructions given to attach the battery cables (positive cable first). | |
| WARNING Connect positive (+) 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. (00068a) | ||
| 4. | Install the seat and side covers according to the procedures in the service manual. | |
| 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) | ||
| 5. | Align the headlamp according to the instructions in the service manual. | |
| 6. | Add engine oil. See the service manual. | |
| 7. | Test the oil temperature gauge. Turn the ignition switch to ON, but do not start the engine. The gauge should illuminate and read the ambient temperature or remain pegged at the lowest graduation. | |
| 8. | Start the engine. With the engine running, the oil temperature should rise as the engine warms up to 230 °F (110 °C) at operating temperature. |
SERVICE PARTS
Figure 3. Service Parts, Fairing Mount Two Inch Oil Temperature Gauge
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Oil temperature gauge | Not sold separately |
2 | Support bracket, two-inch (51 mm) diameter gauge | 74655-05 |
3 | Lock nut, #8-32, with nylon insert (2) | 7864 |
4 | Sending unit, oil temperature gauge | 72357-04 |
5 | Adapter fitting, 3/8 NPT external-1/8 NPT internal thread | Not Sold Separately |
6 | Wiring harness, oil temperature gauge | Not Sold Separately |
7 | Ring terminal, #18-22 AWG, #6 stud, pre-insulated (4) | 9856 |
8 | Cable strap (6) | 10006 |
9 | Sealed splice connector, blue (2, not used in this application) | 70586-93 |
Item mentioned in text, but not included in kit: | ||
A | Hex nut, #6-32, with lockwasher (3) | |