FLHT OIL PRESSURE AND AIR TEMPERATURE GAUGE KIT
J018752011-07-26
GENERAL
Kit Number
77439-00
74459-00 - Installation Hardware Only (No Gauges)
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
Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
Separate purchase of LOCTITE® 565 Thread Sealant is required for proper installation of this kit. LOCTITE can be purchased from any Harley-Davidson dealer.
2004 and Later Models: Do not require installation of items 6, 7 and 8 from this kit.
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
Oil Pressure Sending Unit
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
| 1. | Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. NOTE For 2002 to 2003 models: See Figure 2. Remove the two screws securing the ECM and remove the ECM to access the electrical bracket. | 
Figure 1. Electrical Bracket: 2000-2001 Fuel Injected Models (Magnetti-Marelli) 
Figure 2. Electrical Bracket (ECM Removed) 2002-2003 Fuel Injected Models (Delphi) | ||||||||||||||
| 2. | For 2004 and later models: Proceed to the Gauges section. For 2000 to 2003 models: See Figure 1 , Figure 2 and Figure 3 for the applicable model and locate the sensor harness connector (2-piece mini-Deutsch® connector). | 
Figure 3. Ignition Module - Carbureted Models | ||||||||||||||
| 3. | Locate the oil pressure sending unit at the front right side of the crankcase and pull wire socket from terminal of the oil pressure sending unit. | |||||||||||||||
| 4. | Carefully draw the conduit and the pin side of mini-Deutsch connector forward and then up between the rear brake master cylinder reservoir and the frame downtube to area of the rear brake pedal. | |||||||||||||||
| 5. | See Figure 4. Remove the secondary locking wedge (3) from the pin side of the connector with a needle nose pliers. | 
Figure 4. Deutsch Connector Pin Side (2-pin connector shown) | ||||||||||||||
| 6. | Gently press terminal latches inside pin housing and back out the pin in chamber #1 through the hole in wire seal. | |||||||||||||||
| 7. | Pull the oil sending unit wire through conduit and remove wire. Note the routing of the wire. | |||||||||||||||
| 8. | See Figure 9. Route the jumper (6) pins through the conduit from the kit in the same direction as the original wire noted in Step 7. Use cable straps to secure to the wire bundle. | |||||||||||||||
| 9. | See Figure 5. Locate pin chambers #1 and #2 on pin side of connector. Insert brown/green jumper pin into chamber #2 and feed until it clicks into place. Verify that pin will not back out of the chamber by giving a slight tug on the wire to confirm that it is locked. | 
Figure 5. Route Oil Sending Unit Connector | ||||||||||||||
| 10. | Insert green/yellow jumper pin to chamber #1 and repeat steps performed in Step 9. | |||||||||||||||
| 11. | Insert tapered end of secondary locking wedge into the pin housing and press down until it snaps in place. The wedge fits in the center groove within the pin housing and holds the terminal latches tightly closed. | |||||||||||||||
| 12. | Remove original oil pressure sending unit from crankcase with a 15/16 inch open end crow foot wrench. | |||||||||||||||
| 13. | Apply LOCTITE® 565 Thread Sealant to threads on the new oil pressure sending unit. | |||||||||||||||
| 14. | See Figure 9. Start the oil pressure sending unit (7) into crankcase bore. Tighten switch to 11–14 N·m (8–10 ft-lbs) with a 1-1/16 inch open end crow foot wrench. | |||||||||||||||
| 15. | Attach connector to oil pressure sending unit. |
Gauges
| 1. | Follow applicable service manual instructions to remove the outer fairing. | |||||
| 2. | Remove plastic plugs from the gauge holes in inner fairing. | |||||
| 3. | See Figure 9. Install gauges (1 and 2) in the inner fairing. While seated on the motorcycle, the air temperature gauge installs in the hole on the left side of the radio tray, and the oil pressure gauge installs in the hole on the right side of the radio tray. | |||||
| 4. | For each gauge, slide back clamp (4) over the gauge studs. Verify that the tab (A or B) on bracket engages slot at bottom of inner fairing bore. | |||||
| 5. | Loosely install hex nuts (5) on studs. Verify that the gauge is properly aligned and then tighten nuts securely. | |||||
| 6. | For 2000-2007 Models: See Figure 6. Install the air temperature sensor in the location shown (2) by pushing the post on the connector into the hole in the fairing support. For 2008 and Later Models: See Figure 7. Remove frame plug (1). Push sensor post into hole to install sensor. Secure wire harness with cable strap from the kit. | 
Figure 6. Location of Air Temperature Sensor (outer fairing removed) - 2000-2007 Models | ||||
| 7. | See Figure 8. Refer to the wire colors on the schematic to locate interconnect wire harness connectors 112, 113, 114, 115 and 107. Mate interconnect wire harness connectors to the gauges and sensor as shown in the schematic. | |||||
| 8. | Follow applicable service manual instructions to install the outer fairing. | |||||
| 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) | ||||||
| 9. | Refer to the service manual and follow the instructions given to install the battery, positive cable first. | |||||
| 10. | Refer to the service manual, and follow instructions to install the seat. |
WARNINGAfter 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)
| 1 | Frame plug |
| 2 | Air temperature sensor |
| 3 | Steering head |
Figure 7. Location of Air Temperature Sensor - 2008 and Later Models
| 1 | Oil pressure |
| 2 | Air temperature |
| 3 | Lead wires from interconnect harness |
| 4 | Air temperature sensor |
Figure 8. Wiring Schematic
SERVICE PARTS
Figure 9. Service Parts: FLHT Gauge Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Air temperature gauge | 75109-96B |
2 | Oil pressure gauge | 75032-99A |
3 | Air temperature sensor | 74419-96A |
4 | Back clamp, 2-inch (2) | 67352-96A |
5 | Metric hex nut (4) | 67043-96 |
6 | Jumper, oil pressure gauge | 32806-00 |
7 | Sending unit, oil pressure | 74438-99 |
8 | Conduit | Not Sold Separately |
Items mentioned in text, but not included in kit: | ||
- | Light bulb, replacement | 67445-00 |
A | Alignment tab | |
B | Alignment tab | |