w w w. h d o n l i n e s h o p. d e TWO-INCH TACHOMETER KIT GENERAL INSTALLATION -J03991 REV Kit Number Models Kit Contents

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1 -J0399 REV GENERAL Kit Number A Models This kit fits: 004 and later FXD, FXDC, FXDX, and FXDWG 004 and later Softail (exept FLSTN) 004 and later FLHR/C 004 and later XL 006 and later FXDB and FXD35 Kit Contents See Figure 3 and Table. Additional Tools Required Installation of this kit will also require the use of special tools and additional parts and supplies which are available from any Harley-Davidson dealer. Additional Parts Required The two inch speedometer is designed to be used with a Harley-Davidson Genuine Motor Accessories two inch gauge housing (sold separately) and a gauge bracket kit (sold separately). 004 to 006 XL, FXD and FXDC models equipped with a.0 inch speedometer require additional purchase of harness, part number 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 the plastic and rubber. The rider's safety depends 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. (00333a) 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. TWO-INCH TACHOMETER KIT It is possible to overload your motorcycle's charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle's charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00b) When 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. (0030a) This kit requires up to 00 milliamps additional current from the electrical system. INSTALLATION Prepare the Motorcycle Gasoline can drain from quick-connect fitting when removing fuel line. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0067a). For EFI models: Follow the instructions found in the Service Manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line.. For all models: Follow the instructions found in the Service Manual to remove the seat and any side covers. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect the negative (-) battery cable from the battery. -J0399 of 6

2 is008 Excessive pressure can build in the fuel tank if vapor valve is not mounted vertically with long fitting to top. Leaks due to excessive pressure can cause a fire or explosion, which could result in death or serious injury. (0065a) 4. For carbureted models: Turn the fuel supply valve to OFF. Remove the fuel line from the valve. 5. Follow the instructions in the Service Manual to remove the fuel tank. 6. For all models except FLHR: Follow the instructions in the Service Manual to remove the headlamp housing. 7. For FLHR: Follow the instructions in the bracket kit to remove the handlebar shroud. Install the Gauge Bracket. Follow the instructions in the bracket kit to install the selected gauge bracket.. Select from the two-inch tachometer kit, the rubber isolation gasket. Lubricating the gasket with soap and water will make installation of the gasket easier. 3. Fit the perimeter groove in the rubber isolation gasket to the inside edge of the bracket. Tachometer Only: Route the Wire Harness For installation with a two-inch speedometer, see Tachometer with Speedometer: Route the Wire Harness or refer to the two-inch speedometer instructions.. Select the harness and install the grommet.. Route the harness through the gauge housing. 3. Route the two inch tachometer wire harness conduit through the forks and upper triple clamp, along the frame backbone to the area under the seat. Tachometer Only: Black Lead to Ground. Use the wiring diagrams and the Service Manual, to locate the ground for the year and model and route the two-inch tachometer harness ground (BK) lead to the ground. For Dyna: See Figure. At either of the rear ground studs under the fuse block. For Softail: See Figure. Under the seat, near the fuse block, on the left side of the vehicle. For FLHR/C: See Figure 3. Under the seat directly in front of the battery. For XL Sportster:See Figure 4. On the engine cases behind the starter. is009 is0030 Figure. Dyna Ground Figure. Softail Ground Figure 3. FLHR Ground -J0399 of 6

3 is003 is004 Figure 6. Softail Data Link is0040 Figure 4. XL Ground Tachometer Only: Route the Tachometer Lead (LGN/V) to Data Link Connector [9A]. Use the Service Manual to locate the data link connector [9A] for the model motorcycle. Remove the side panels as required. For Dyna: See Figure 5. At either of the rear ground studs under the fuse block. For Softail: See Figure 6. On the left side of the battery in left frame rail. For FLHR/C: See Figure 7. Under the seat directly in front of the battery. For XL: See Figure 8. On the engine cases behind the starter.. Route the signal light green and violet lead (LGN/V) to the data link. 3. Identify the signal (LGN/V) lead (cavity 3) from the data link and cut the lead / inch from the connector. is0038 Figure 7. FLHR Data Link is0039 Figure 8. Data Link Connector [9A] (XL shown) Figure 5. FXD Data Link Tachometer Only: Route the Power (O/W) Lead to Power. For all models except XL: Route the power (O/W) lead to the fuse block.. For the XL: Route the power (O/W) lead to the main wire harness along side the backbone. -J of 6

4 Tachometer Only: Adapt the Fuse Block to the Power Lead. For all models except XL: Access the fuse block and remove the cover.. For FLHR: See Figure 0. Select the power adapter from the kit and install the touring terminated end of the adapter into the socket on the back of the fuse block marked P&A IGN. For Dyna and Softail: Install the Dyna/Softail terminated end of the power (O/W) lead from the adapter into the socket on the back of the fuse block marked as OPEN. 3. Cut off the opposite terminal at the crimp. See Figure 0. The power adapter will be spliced to the tachometer harness power lead (O/W). See. is004 Figure 9. Fuse Block Cover with P&A IGN Mark is005. Touring models terminal. Dyna/Softail models terminal Figure 0. Power Adapter 4. See Figure. Install the Amp fuse in the P&A IGN (Softail/FLHR) or OPEN (FXD/FXDX/FXDWG) slot. 5. Install the fuse block and the cover. is0036 Figure. Socket for Amp Fuse (004 FXDWG shown) Tachometer Only: Splice Power/Data Link Leads. Adjust the length of the tachometer harness leads to the power adapter and the data link.. Strip 3/8 inch of insulation from the ends of the leads, the power adapter and the data link. 3. See Figure. Splice the leads: Splice the power lead to power adapter with a into splice configuration. Splice the LGN/V lead from the data link [9A] to the tachometer signal (LGN/V) lead with a into splice configuration. Gently hold the seal connector from the kit in the red jaws of the Packard Crimp Tool (HD-385-8). Feed the stripped lead(s) up to the wire stop inside the metal insert in one half of the connector. Squeeze the tool to crimp the metal insert. The tool automatically opens when finished. Repeat for the other end of the connector to capture one or two striped leads including, if required, the fuse block power adapter. Be sure to follow manufacturer's instructions when using the UltraTorch UT-00 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a) Avoid directing the heat toward any fuel system component. Extreme heat can cause a fuel ignition explosion resulting in death or serious injury. Avoid directing heat toward any electrical system component other than the connectors on which heatshrink work is being performed. Always keep hands away from tool tip area and heat shrink attachment. 4. Using the UltraTorch UT-00 (HD-39969) or other radiant heating device, heat the crimped splice form the center of the crimp out to each end until the sealant exudes out both ends of the connector and the tubing assumes a smooth cylindrical appearance. -J of 6

5 is0035 Table. Connector [08] Cavity Numbers to Lead Colors Cavity Lead Color Description LGN/V Tachometer signal 3 O/W Accessory 6 BK Ground. into. into Figure. Splice Configurations Tachometer Only: Terminate the Ground Lead. If required, adjust the length of the ground lead (BK) from the tachometer harness and cut the lead to fit.. If necessary, strip 3/8 inch of insulation from end of the ground (BK) lead. 3. Crimp the correct sized ring terminal on the bare wire of the ground lead. For Dyna: 5/6 inch ring terminal. For Softail and FLHR: /4 inch ring terminal. For XL: /4 inch ring terminal. 4. Remove the main harness ground fastener and add the ring terminal to the stud. 5. Install the ground fastener and tighten the torque specification found in the Service Manual. Tachometer with -Inch Speedometer: Route the Wire Harness. Follow the instructions in the two-inch speedometer kit to remove the original equipment speedometer and route the speedometer wire harness from the speedometer kit to the main harness connector [08].. Route the terminated leads through the gauge housing and through the grommet. Follow the speedometer harness routing to the connector [08]. 3. Separate the speedometer to tachometer pin and socket connector [08] on the speedometer harness. 4. See Table. Using the.0 inch speedometer and tach harness purchased separately, match the terminated lead colors to cavities, 3, and 6 in the pin connector half and follow Service Manual instructions to insert the pins into the connector. Connect the Tachometer Harness to the Tachometer. Thread the two stand-offs from the gauge housing kit onto the back of the tachometer.. Orient the gauge to the rider and slide the tachometer into the isolation gasket in the gauge bracket. Lubricating the isolation gasket with soap and water will make the installation easier. 3. Fit the harness connector to the connector on the back of the tachometer. 4. Install the flat head screws from the housing kit. Tighten the flat head screws to 0-30 in-lbs (.-3.4 Nm). Inspect and Secure the Wire Harness. Bounce motorcycle to look for pinch points between suspension components and tachometer wire harness.. Turn front forks lock to lock to look for pinch points. 3. Check for slack in wiring so that handlebar movement is not restricted. 4. Check clearance from heat sources along harness. 5. Bundle the tachometer harness to the main wiring harness along frame backbone by using cable straps to support wires so they do not chafe or contact hot or moving points. Return Motorcycle to Service. Replace the fuel tank and attach fuel line or fittings.. Connect the negative (-) battery cable. 3. Install the maxi-fuse. 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) 4. Install the side covers and the seat. Test Installation. To test tachometer, turn ignition to ON. Start engine. With engine idling, tachometer should indicate idle RPM (950 to 50 RPM).. Tachometer should respond to changes in throttle settings. -J of 6

6 SERVICE PARTS See Figure 3 and Table. is Item Figure 3. Service Parts: Two-Inch Tachometer Kit Table. Service Parts: Two-Inch Tachometer Kit Description (Quantity) Part Number Fuse, A "Mini" Wiring harness, tachometer only Grommet Not sold separately 509 Harness, fuse block adapter Sealed connector, 4-6 gauge Ring terminal, /4 inch 9858 Ring terminal, 5/6 inch Cable strap (0) Isolation gasket Tachometer Not sold separately -J of 6