INSTRUCTIONS - HARLEY-DAVIDSON Rostock GmbH
Contents
1. NOTE Make certain the slot in the terminal faces the tang in the chamber for proper installation On the socket side of the connector tangs are at the top of each chamber so the socket terminal slot on the same side as the crimp tails must face upward Up and down can be determined by the position of the release button used to separate the pin and socket halves the button always being the top of the connector 2 For 1998 and earlier Remove tape from the speedometer wires and insert the terminals into connector 20 as follows Instrument Wire Color Cavity Number Speedometer Orange white 1 Speedometer White green 2 Speedometer Black 12 Tachometer Orange 6 Tachometer Pink 7 See Figure 11 for cavity number location For 1999 and later Insert the terminals into connector 20 as shown above however since there is not an open 6 cavity in connector 20 for 1999 and later models the Orange wire will need to be spliced into the Orange White wire coming out of the speedometer at a convenient location Refer to SEALED BUTT CONNECTORS in the Service Manual for a complete procedure 101288 clip terminal off Orange wire end 11 10 Conduit from kit Corresponds to wires listed in Service Parts 3 of 6 i00235 eo connector Tachometer ground wire Socket terminal Figure 9 Connecting Tachometer amp Speedometer Grounds 3 See Figure 2 After all wires are in place close the secon2. 11 1050a8x NO TE Pin connector half shown Latches identical on socket half connector Figure 4 Depressing Terminal Latches Slide connector 65 forward to disengage connector from T stud See Figure 3 Depress external latch 4 and unplug the connector See Figure 3 Remove the secondary locking wedge 6 as follows Insert the blade of a small screwdriver between the socket housing 3 and locking wedge 6 inline with the socket holes Turn the screwdriver 90 degrees to pop the wedge up See Figure 4 Gently depress terminal latches inside sock et housing and back out sockets through holes in rear wire seal Cavity letters and wire colors are shown in Figure 3 Cavity letters are molded in the housing Carefully note how the speed sensor harness is routed Pull the speed sensor harness forward through the cable straps Cut cable straps only if required Cut cable strap holding speedometer and bracket to mir ror Place the speedometer and bracket on a clean work bench REMOVING SPEEDOMETER LEADS FROM CONNECTOR 20 1998 AND EARLIER MODELS 1 See Figure 2 Bend back the latch slightly and free one side of secondary lock then repeat the step to release the other side Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing Looking in the terminal side of the connector opposite secondary lock take note of cavity next to each terminal See Figure 5 Remove the
3. M STOCK BRACKET 1 Note location of all indicator light components mounted in speedometer bracket Each indicator lamp has the lamp s function printed on one of the lamps leads Remove the two screws that secure the indicator light components to the speedometer bracket Retain screws and indicator light components for installation on speedometer tachometer bracket later 2 See Figure 6 Unscrew boot 1 if necessary from speedometer reset switch by turning it counterclockwise Remove two cover screws 2 and the rear cover 3 3 Note position of rear speedometer gasket 4 and remove it Gently push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket 4 Do not remove front gasket 5 from the speedometer 6 2 of 6 Figure 7 Speedometer in Double Bracket INSTALLING SPEEDOMETER IN DOUBLE BRACKET NOTE The tachometer will be mounted in the right side of the double bracket as received in the kit 1 See Figure 7 Feed wires from speedometer through front of left opening in double bracket Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation 2 Insert speedometer in double bracket making certain wire guides are aligned at bottom of bracket 3 Place rear gasket in position and align gasket tabs with anti rotational slots Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while
4. be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a Final Checks and Adjustments 1 If necessary adjust the handlebar to the rider s normal position Hold the handlebar and loosen rear clamp bolts Position and adjust handlebars and tighten rear screws to 12 15 ft lbs 16 3 20 3 Nm J01523 Bezel and color strip i Figure 10 Tachometer amp Speedometer Installed x0014a7x housing Arrow must point to external Socket housing Figure 11 Secondary Lock Positioning NOTE When handlebar installation is complete the upper and lower clamps have contact with the cast in boss in front and have aslight gap at the rear 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 2 Connect the battery cables positive cable first 3 Turn ignition light switch to ON Check that the indicator lights signal lights and headlamp all function properly 4 Start the engine check the tachometer operation and check that the indicator lights are working correctly 5 If tachometer does not function see Figure 12 and check that all wiring connections were correctly made 6 Test ride motorcycle to verify speedometer is functioning pro
5. cMOTOR2 HARLEY DAVIDSON WY General This kit is designed for installation on 1995 2003 XLH 883 model motorcycles equipped with an electronic speedometer and no tachometer Does not fit 1999 and later XL883 Custom models See Service Parts illustration for kit contents NOTE USE THE APPROPRIATE SERVICE MANUAL PROCEDURE Service Manuals are available from your Harley Davidson dealer If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Installation GENERAL To install this kit you will be removing the following fuel tank speedometer bracket speedometer and indicator lights in base of speedometer bracket You will also have to remove the seat disconnect the electronic speedometer harness from connector 65 under the seat and disconnect connector 20 under the headlight bracket Read all the instructions carefully before you begin the tachometer installation Connector numbers in brackets for example 65 are the identifying numbers used in Service Manual wiring diagrams Removal ELECTRONIC SPEEDOMETER AND BRACKET To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery expl
6. dary locks on the socket housing INSTALLING INDICATOR LIGHTS ON DUAL BRACKET 1 See Figure 10 Place the indicator light bezel and color strip on front of dual bracket Make certain color strip stays in position on locating pins 2 Install indicator light socket assembly on rear of dual bracket making sure locating pins on bezel enter holes in socket assembly Install two mounting screws INSTALLING SPEEDOMETER TACHOMETER 1 Hang speedometer tachometer assembly on mirror with cable strap and connect wiring as follows 2 Route speedometer 3 wire harness back to its original position See Figure 3 Insert wires and terminals into connector 65 3 See Figure 11 Install secondary lock with arrow positioned as shown NOTE If the secondary lock wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The secondary lock indicates when terminals are not properly installed by not entering its fully installed position 4 Install cable straps to replace any that were removed 5 Mate halves of connector 65 6 See Figure 10 Install soeedometer tachometer assembly on handlebar clamp as shown using original fasteners Tighten snug tight Connect and install connector 20 Refer to applicable Service Manual and install fuel tank Refer to applicable Service Manual and install seat WARNING After installing seat pull upward on front of seat to
7. following wires and terminals from connector 20 by following the procedure in step 4 f1287b2x Secondary Locks Open Figure 5 Terminal Numbers Stamped On Secondary Locks 12 place socket housing shown J01523 i00590b eps Figure 6 Wire Color Cavity Number Orange white 1 White green 2 Black 12 4 See Figure 2 With the flat side of pick tool against the ter minal insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick away from the termi nal and gently tug on wire to pull terminal from chamber Do not tug on the wire until the tang is released or the ter minal will be difficult to remove A click is heard if the tang is engaged but then inadvertently released Repeat the step without releasing the tang 5 Slide the wires removed in step 4 above out of the plastic conduit covering the wires connected to connector 20 1999 AND LATER MODELS 1 Refer to the Deutsch Electrical Connector section in Section 7 of the 1999 or later XLH Service Manual Depress external latches on socket half of connector and separate socket and pin halves Follow the instructions for Removing and Installing Sockets and remove the following wires from the connector 20 Wire Color Cavity Number Orange white 1 White green 2 Black 12 2 Slide the wires removed in Step 1 above out of the plastic conduit covering the wires connected to the connector 20 REMOVING SPEEDOMETER FRO
8. osion which could result in death or serious injury 00049a J01523 a Remove handlebar clamp screws securing speedometer bracket Gently move speedometer forward and hang from mirror with cable strap Refer to applicable Service Manual and remove seat and fuel tank following Service Manual procedures N A WARNING Stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002a 3 Remove the two bolts that secure the headlamp bracket and allow headlamp and bracket to tilt forward as shown in Figure 1 4 See Figure 2 Press the button on connector 20 to unplug a Follow the speed sensor harness connected to speedometer that is routed down frame backbone to con nector 65 under seat INSTRUCTIONS REV 9 18 03 Kit Number 67182 95D XLH TACHOMETER KIT Socket terminal Secondary lock f1298x2x L 1 Open secondary lock 2 Insert pick into cavity 3 Pivot end of pick to release tang 4 Gently tug on wire to remove terminal Figure 2 Amp Multilock Socket Connector Wire Removal i00577 Cavity A Red Cavity B White 1 Socket terminal and wire 2 Wire seal 3 Socket housing 4 External latch 5 Internal seal 6 Secondary lock Cavity C Black Figure 3 3 Place Deutsch Socket Connector 1 of 6 10
9. perly 4 of 6 i00237 Three wire speed sensor _ harness not shown See Figure 9 for details of ground splice SocketNo 1 2 5 10 See socket housing below for lead location in socket housing 1287b2x Socket housing as viewed from terminal end SOCKET NO WIRE COLORS OR MARKING 9 GN Y OP Green yellow oil pressure 1 Orange white 10 O or BE Orange or blue White green 11 BK black BN RT Brown right turn indicator 12 BK black ground for speedo and tach W HB WHITE High beam V LT Violet left turn indicator Orange white Pink TN N Tan neutral indicator NOTE The indicator light wires socket no 3 4 5 8 9 10 and 11 are all black To identify the mating wire color in pin housing and the circuit function the wires are marked with white letters giving color and circuit function OSNOARON NOTE ON 1998 MODELS In 1998 the 12 place connector 20 was replaced with a 14 place connector 20 Wires 1 12 are the same for both the 12 place and the 14 place connectors Wires 13 and 14 were added for a police and engine check function Figure 12 Speedometer Tachometer Wiring Diagram J01523 5 of 6 SMa TOR Part No 67182 95D Date 9 03 Service Parts XLH Tachometer Kit i03086 eps Description Part No Description Part No Cable straps 6 10006 14 Socket Deutsch socket 68945 98 Screws cover 2 Pink wire 8 32
10. pushing gasket into position at the opposite side 4 Check that reset switch is in position and that all wires are positioned so they will not be pinched by rear cover 5 Install rear cover on speedometer install cover screws and reset switch boot ASSEMBLING TACHOMETER HARNESS 1 See Figure 8 As dictated by model year assemble one of the harnesses shown from wires conduit and connector provided in kit The connector cavity numbers are shown on socket housing 11 and wires must be inserted as follows Wire Color Cavity Number Orange 1 Black 2 Pink 3 2 This harness will plug directly into the back of the tachometer After plugging wire ends into connector shown cover wires with conduit from kit CONNECTING SPEEDOMETER TACH GROUND LEADS 1 Cut speedometer black ground lead 1 in from existing terminal Strip 3 8 in insulation from both the wire ends adjacent to the cut Strip 3 8 in insulation from tachometer black ground lead See Figure 9 Using one of the butt connectors from the kit connect the ground leads as shown Refer to SEALED BUTT CONNECTORS in the Service Manual for a complete procedure J01523 CONNECTING SPEEDOMETER TACHOMETER LEADS TO CONNECTOR 20 1 Tape the three speedometer wires with the socket terminals on their ends together and slide them through the large conduit so the terminals are positioned next to connector 20 Place the tachometer harness next to the connector also
11. x 11 64 in 2361 15 Socket Amp socket 68946 98 Gasket rear 67104 95 Pink wire Bracket speedo tach 67338 97 16 Socket no terminal 68947 98 Gasket front 67121 95 Black wire Cover tach rear 67319 95 17 Tachometer light bulb with color diffuser Tachometer 67321 99 for 1998 and later models 67385 98 Butt splice blue 2 70586 93 18 Socket Deutsch socket 68987 99 Hose clamp 2 9946 Pink wire 1 2 in vinyl conduit 9 in long not sold 19 Conduit 5 16 vinyl 9 long not sold 6 place socket housing 72081 99 Socket Deutsch socket 68943 98 Not shown See Figure 8 for instructions on Orange wire assembling connector wires and conduit into a Socket Amp 68944 98 harness Orange wire J01523 6 of 6
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