HARLEY DAVIDSON FRONT TURN SIGNAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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REMOVAL 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. Purge the high-pressure fuel line and disconnect the fuel line following the instructions in the appropriate Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse following the instructions in the appropriate Service Manual. 3. Remove the seat following the instructions in the appropriate Service Manual. Save all seat mounting hardware. NOTE When moving the fuel tank back, do not damage the fuel gauge wires clipped to the frame under the left side of the fuel tank. 4. Remove the front and rear fuel tank mounting hardware following the instructions in the appropriate Service Manual. Move the fuel tank back on the frame to gain access to the tabs on the steering head harness shield. 5. See Figure 1. Disengage the tabs (2) from the holes (3) on each side of the frame and remove the shield (1). 6. Pull the wire harness down from inside the frame enough to disconnect the white (left) [31L] and black (right) [31R] 3-place turn signal connectors. Set aside the frame-side connector halves. 7. Remove the socket terminals from the lamp-side connector halves following the instructions in the appropriate Service Manual. Make note of the wire colors installed in the cavities of each connector, which should be: Left side (white connector): a. Black [BK] wire in cavity 1 b. Violet [V] wire in cavity 2 c. Blue [BE] wire (if installed) in cavity 3 Right side (black connector): a. Black [BK] wire in cavity 1 b. Brown [BN] wire in cavity 2 c. Blue wire [BE] (if installed) in cavity

HARLEY DAVIDSON LED FUEL GAUGE KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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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. 1. 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. 2. See Figure 2. Depress the pin on the socket terminal side of the connector, and pull apart the pin and socket halves. 3. 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. 4. For Carbureted Models: See Figure 2. Remove the fuel gauge by firmly grasping and carefully pulling up (do NOT twist) on the gauge just far enough to free it from the fuel tank. Disconnect the two sending unit connectors. Feed the conduit and two wires up through the tube while removing the gauge. Remove and discard the fuel gauge. For Fuel-Injected Models: See Figure 2. 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. 5. Remove and discard the rubber gasket. INSTALLATION For Kit Numbers 75084-04B or 75237-03B 1. 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. 2. 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. 3. See Figure 2. 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

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