BILLET LED FUEL GAUGE KIT, THE SKULL COLLECTION

INSTRUCTIONS

2006-04-01J03931

GENERAL

Kit Number

75095-05

Models

• 2004 and later FXDL/I (Dyna

Low Rider

), FXDB, FXDWG/I

(Wide Glide

) and 2007 FXDC models,

• 2004 and later carbureted or fuel-injected Softail

models,

• 2001-2003 fuel-injected Softail models except Deuce

™

• 2003 and later carbureted FLHR (Road King

) or FLHRS

(Road King

Custom) models,

• 2001 and later fuel-injected FLHRI (Road King

), FLHRCI

(Road King

Classic) or FLHRSI (Road King

Custom)

models.

NOTE

The instrument-panel mounted OE low-fuel warning lamp

function will be disabled when installing this kit.

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 available from

a Harley-Davidson Dealer.

Kit Contents

See Figure 3 and Table 1.

INSTALLATION

WARNING

To prevent accidental vehicle start-up, which could cause

death or serious injury, disconnect negative (-) battery

cable before proceeding. (00048a)

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.

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)

Analog Fuel Gauge Removal

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 3. Depress the pin on the socket terminal side

of the connector, and pull apart the pin and socket halves.

3. Use a pick (Snap-On TT600-3) to remove the terminals,

or clip off the wires.

4. For Carbureted Models: See Figure 3. Remove the fuel

gauge by firmly grasping and carefully pulling up (Do not

twist) just far enough to free the gauge 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 3. 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.

LED Gauge Installation

1. See Figure 3. Assemble the new O-ring (2) to the LED fuel

gauge (1) from the kit.

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Many Harley-Davidson® Parts & Accessories are made of plastics and metals which can be recycled.

J03931

Please dispose of materials responsibly.

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Orange wire to "12V O"1.

Gray wire to "3V GR"2.

Black wire to "GND BK"3.

Yellow/white wire to "Y/W"4.

Figure 1. Wire Connections

2. Obtain the wiring harness from the kit. See Figure 1. Fasten

the Orange wire (1) ring terminal to the gauge connection

marked "12V" and "O" with one of the Phillips-head screws

and star washers.

3. Fasten the Black wire (3) ring terminal to the connection

point marked "GND" and "BK", and the Yellow/ White wire

(4) ring terminal to the connection marked "Y/W".

4. For 2001-2003 fuel-injected models, the Gray wire (2)

will not be used. Cut the wire short and tape over the end

with electrical tape. The Phillips-head screw can be

installed back into the hole marked "3V" and "GR". For

2004 and later carbureted models, the Gray wire (2) will

not be used. Cut the wire short and tape over the end with

electrical tape. The Phillips-head screw can be installed

back into the hole marked "3V" and "GR". For 2004 and

later fuel-injected models, fasten the Gray wire (2) ring

terminal to the gauge connection marked "3V" and "GR".

For ALL models: Tighten all four Phillips-head screws to

0.4–0.9 N·m (4–7 in-lbs).

5. While carefully lowering the fuel gauge, feed the wire

harness down into the drain tube until the long Gray wire

(B) and 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 downward until it snaps into

place.

NOTE

DO NOT attempt to connect the Gray wire socket terminal

into the 4-place pin housing.

is00426

Cavity 1: Orange1.

Cavity 2: Yellow/white2.

Cavity 3: Gray3.

Cavity 4: Black4.

Four-pin connector5.

Figure 2. Four-Pin Connector (viewed from wire end)

6. See Figure 2 and Figure 3. Install the wires with pin

terminals (C) into the correct cavities of the 4-place pin

housing (4) from the kit. See the chart below and the AMP

MULTILOCK ELECTRICAL CONNECTORS, INSTALLING

SOCKET/PIN TERMINALS section in the Service Manual.

• Cavity 1: Orange

• Cavity 2: Yellow/White

• Cavity 3: Gray

• Cavity 4: Black

12. At the bottom left side of the fuel tank, mate the completed

pin housing to the socket housing [117B] disconnected in

Step 3. 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).

13. The OE gauge harness did not have the Gray wire (with

socket terminal) that is included in the kit wiring harness:

• For 2001-2003 fuel-injected models, the Gray wire will not

be used. Cut the wire short and tape over the end with

electrical tape.

• For 2004 and later carbureted models, the Gray wire will

not be used. Cut the wire short and tape over the end with

electrical tape.

• For 2004 and later fuel-injected models, the Gray wire

will replace the Yellow/White wire found in cavity 9 of the

speedometer connector [39B] (Touring or Softail models) or

instrument assembly connector [20] (Dyna) later in the

installation (see Step 15).

14. Connect the long Gray wire in the following manner:

a. Install the Gray wire into Cavity 3 of the fuel gauge

socket housing [117B] on the motorcycle main harness.

b. Route the Gray wire through the tunnel under the fuel

tank, then up the front of the tank.

c. Follow the instructions in the Service Manual to gain

access to the speedometer connector [39B] (Touring or

Softail) or instrument connector [20] (Dyna).

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d. Locate the Yellow/White wire in Cavity 9 of the

connector, and remove the wire and terminal from the

connector. Refer to the PACKARD ELECTRICAL

CONNECTORS section in the Service Manual. Following

removal, either cut the Yellow/ White wire short and tape

over the end with electrical tape, or fold the wire back

on itself and tape over the end.

e. Route the Gray wire to the connector and install into the

now-empty Cavity 9. Re-install the rear cover of the

speedometer or instrument assembly connector as

required. See the Service Manual.

f. Install tape or wire ties along the path of the gray wire

to secure it. Proceed to Step 16.

15. 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 so equipped).

16. Connect battery cables, negative (-) cable first.

17. Refer to the Owner's Manual and follow the instructions

given to re-attach the negative battery cable and install the

seat.

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.

SERVICE PARTS

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Figure 3. Service Parts: Skull LED Fuel Gauge Kit

Table 1. Service Parts: Skull LED Fuel Gauge Kit

Part NumberDescription (Quantity)Item

Not Sold SeparatelyFuel gauge, LED Skull1

27730-04O-ring, fuel gauge2

70026-05Wiring harness3

72904-01BKPin housing, 4-way4

75003-04Hardware Kit (Service only - contains items 6 and 7)5

Not Sold SeparatelyPhillps-head screw (4)6

Not Sold SeparatelyStar washer (4)7

Items mentioned in text:

Gray wire extensionA

Wire conduitB

Pin terminalsC

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