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FLUSH-MOUNT LED FUEL GAUGE AND GAS CAP KIT
J052642023-05-03
GENERAL
Kit Number
62811-08C, 62823-08D, 62818-06G, 62910-09D, 62910-06D, 62823-06D (chrome)
75020-08C, 75027-08D, 75327-09D, 75014-06D (black)
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
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.
Kit Contents
See Figure 12 , Table 1 and Table 2.
INSTALLATION
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)
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 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 a mixture of equal parts of isopropyl alcohol and distilled water.
3. See Figure 1. Install gas cap into fuel tank.
4. To lock, push on gas cap and rotate clockwise one-eighth turn. To unlock, push down on gas cap and rotate counterclockwise one-eighth turn.
5. See Figure 2. Before removing adhesive backing, note position of notch on inside diameter of trim ring.
NOTE
As the trim ring is rotated, there will be 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.
6. See Figure 3. With the notch pointing toward front of motorcycle, rotate trim ring slightly to determine best position of bottom trim ring against contour of the fuel tank.
Figure 1. Screw in Gas Cap
1Notch
Figure 2. Note Position of Notch on Trim Ring
7. See Figure 4. Mark position of trim ring with masking tape (1) or grease pencil.
8. Carefully cut masking tape at location (2) with a hobby knife making sure not to scratch trim ring or paint surface on fuel tank.
9. Peel adhesive backing off trim ring.
10. Using gas cap to center and masking tape (or grease pencil mark) to align, press trim ring firmly into position for about ten seconds.
11. Peel masking tape off (or remove grease pencil mark) from trim ring and fuel tank.
NOTE
Allow trim ring to cure for about 5-7 minutes before continuing with kit installation.
Figure 3. Determine Position for Trim Ring
1Masking tape
2Cut masking tape
Figure 4. Align Trim Ring and Press into Place
Install Flush-Mount LED Fuel Gauge
1. Remove the seat following the instructions in the owner's manual.
2. Disconnect battery cables, negative (-) cable first.
3. Remove stock fuel gauge. Refer to service manual for instructions.
4. Insert three wires down the tube of fuel tank from LED fuel gauge.
5. See Figure 5 and Figure 6. Insert 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 5. Align Narrow Tab with Front Tabs in Fuel Tank Cup
Figure 6. Align Wide Tab with Rear Tabs in Fuel Tank Cup
6. To open, push 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 8 and Figure 9. 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, push 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 10. To close, insert fuel gauge into housing and push until you hear a CLICK.
10. See Figure 7. 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 equipped).
12. Connect battery cables, positive (+) cable first.
13. Install the seat following the instructions in the owner's 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)
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.
1Terminal 1: Orange
2Terminal 2: Yellow/white
3Terminal 4: Black
4Four-pin kit connector
5Four-pin vehicle connector
6Fuel gauge
Figure 7. Four-Pin Connector
Figure 8. Gauge Housing in Unlocked Position
Figure 9. Gauge Housing in Locked Position
Figure 10. Close Fuel Gauge
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.
1LED segments
2Fuel pump icon
3Photocell location
Figure 11. Gauge Features
SERVICE PARTS
Figure 12. Service Parts; Flush-Mount LED Fuel Gauge and Gas Cap
Table 1. Service Parts: Flush-Mount LED Fuel Gauge and Gas Cap Kit - Chrome Kits
Item
Description
Part Number
Kit
62811-08C
Kit
62823-08D
Kit
62818-06G
Kit
62910-09D
Kit
62910-06D
Kit
62823-06D
Fuel gauge assembly
(includes items 1 through 4)
Not Sold Separately
1
Fuel gauge
63075-08A
63075-08A
63029-06C
63075-08A
63029-06C
63029-06C
2
Gauge housing, Chrome
62814-08
63038-06
63038-06
62945-06
62945-06
62834-07
3
Wiring harness
Not Sold Separately
4
Pin housing, 4-place
72904-01BK
72904-01BK
72904-01BK
72904-01BK
72904-01BK
72904-01BK
5
Chrome trim ring
62887-08
63028-06
63028-06
63045-06A
63045-06A
63039-07
6
Gas cap (includes item 7)
63135-10A
63135-10A
63135-10A
63135-10A
63135-10A
63135-10A
61100052A
61100052A
61100052A
61100052A
61100052A
61100052A
7
O-ring
11900004
11900004
11900004
11900004
11900004
11900004
Items Mentioned in Text
A
Notch
Table 2. Service Parts: Flush-Mount LED Fuel Gauge and Gas Cap Kit - Black Kits
Item
Description
Part Number
Kit 75020-08C
Kit 75027-08D
Kit 75327-09D
Kit 75014-06D
Fuel gauge assembly
(includes items 1 through 4)
Not Sold Separately
1
Fuel gauge
75018-08A
75018-08A
75018-08A
75011-08A
2
Gauge housing, Black
75026-08
75019-08
75013-08
75019-08
3
Wiring harness
Not Sold Separately
4
Pin housing, 4-place
72904-01BK
72904-01BK
72904-01BK
72904-01BK
5
Black trim ring
75022-08
75015-08
75004-08A
75015-08
6
Gas cap (includes item 7)
63136-10C
63136-10C
63136-10C
63136-10C
7
O-ring
11900004
11900004
11900004
11900004