INSTRUCTIONS - Harley
Contents
1. HARLEY DAVIDSON J03133 INSTRUCTIONS REV 06 11 2004 Kit Number 67231 04 FLHR MINI TACH BRACKET KIT General This kit is designed for installation on 1994 and later FLHR except FLHRSEI and 1986 and later Softail models equipped with Chrome Headlight Nacelle Part No 67907 96 This kit requires a 1 mini tach kit and a 2 mini tach housing kit to complete the installation Mini Tach Kits Part No Mini Tach Kit black face 68953 04 Mini Tach Kit silver face 68986 04 Mini Tach Kit metal face 67201 04A Mini Tach Kit nostalgic face 68031 05 Housing Kit Part No Mini Tach Tapered Gauge Housing 67295 04 Mini Tach Standard Gauge Housing 67523 04 See the Service Parts illustration for the contents of this kit 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 per form the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual instructions A Service Manual for your motorcycle is available from your Harley Davidson dealer CAUTION 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 c2. amp assembly Speednut Chrome strip Nut Fender washer Screw Cover plate Screw Figure 1 Nacelle and Handlebar Shroud Components i06414 For 1994 to 2002 1 7 8 in 47 63 mm For 2003 and later 1 5 8 in 41 28 mm 3 13 16 in 96 84 mm 9 32 in dia drill hole Figure 2 Nacelle Components and Hole Locations 2 of 3 Install Tachometer into Bracket Return the Motorcycle to Service 1 Follow the instructions in the mini tach instruction sheet to 1 Follow the directions in the Service Manual and the mini install the tachometer in the bracket tach instruction sheet to secure the wiring and install the fuel tank 2 Following the mini tach instructions attach the wire terminals to the terminal posts on the back of the tachometer 2 Connect the negative battery cable to the battery 3 Follow the instruction sheet that comes with the mini tach housing kit to attach the housing Be netall he seat After installing seat pull upward on front of 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 seri ous injury 00070a 4 Install right sidecover and saddlebag 5 Follow the directions in the instruction sheet to test the operation of the tachometer Part No 67231 04 Date 06 04 SMOTOR o Service Parts i06410 FLHR Mini Tach Bracket Kit Description Quantity Part No Acorn nut 2 7949 Wa
3. e the upper and lower nacelle passing lamp bracket acorn nuts c Apply constant pressure to lower portion of nacelle toward rear of motorcycle and move lower windshield bushings as far back as possible then tighten lower acorn nuts to 18 ft lbs 24 Nm d Apply constant pressure to upper portion of nacelle toward rear of motorcycle and move the upper wind shield bushings as far forward as possible then tighten upper acorn nuts to 18 ft lbs 24 Nm 3 See Figure 1 Remove screw 1 headlamp door chrome ring 2 and headlamp screws 3 Retain screws 1 of 3 Separate electrical connector and and remove headlamp assembly 4 Remove speednut 5 that holds chrome trim strip 6 in place and remove trim Carefully pry off fork lock plate 10 on top of nacelle handle bar shroud to access screws that hold cover in place Under plate remove 2 screws 11 that hold shroud to fork lock Remove nut 7 that secures the handlebar shroud and remove shroud screw 9 and fender washer 8 Install FLHR Mini Tach Bracket Kit on Shroud 1 See Figure 2 Cover the front of the handlebar cover with transparent or masking tape For 1994 to 2002 models Measure and mark hole loca tions 1 and 7 8 in 47 63mm from the bottom front of cover and 3 and 13 16 in 96 84 mm apart and centered on the front face of the shroud For 2003 and later models Measure and mark hole loca tions 1 5 8 in 41 28 from the botto
4. m front of cover and 3 13 16 in 96 84 mm apart and centered on the front face of the shroud NOTE For best results drill the handlebar cover holes on a drill press with the drilling surface level Be sure to use a sharp arill bit when drilling holes in the cover 3 5 Center punch hole locations Drill 1 8 in starter hole and fin ish with a 9 32 in drill bit Remove the tape and any burrs that may have formed Attach tachometer bracket to cover with screws lockwash ers and nuts Tighten to 84 108 in Ibs 9 12 Nm Install the Shroud 1 2 A D a 10 Fit the handlebar shroud over the handlebar clamps Install the screw through the shroud and the nacelle and from the inside of the nacelle fit the fender washer and thread on the nut Tighten the screw to 10 20 in Ibs 1 1 2 3 Nm Install the 2 screws that secure the shroud to the fork lock Install the cover plate Fit chrome strip and reach inside nacelle to install the speed nut Tighten speednut to 15 20 in Ibs 1 7 2 3 Nm Mate the wire connector to the back of the headlamp Install the headlamp with the 8 screws Fit the square shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door chrome ring into place Install the screw at the bottom of the headlamp door Install the windshield J03133 106417 S SEON Oar N Headlamp door Headlamp screw Headl
5. sher 2 6099 Capscrew 2 941 Tach mount 67944 96 J03133 3 0f 3
6. urrent than your vehicle s charging system can produce the electrical consumption can discharge the battery and cause vehi cle electrical system damage See a Harley Davidson dealer for advice about the amount of current con sumed by additional electrical accessories or for nec essary wiring changes 0021 1b Installation Prepare the Motorcycle 1 Follow the Service Manual instructions to remove the seat To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect the negative battery cable 3 Follow the instructions in the Service Manual and in the mini tach kit instruction sheet to remove the fuel tank Wire the Tachometer 1 Follow the instructions in the Service Manual and the mini tach instruction sheet to splice the tachometer wires to the main wire harness and to wire the fuse block 2 Follow the instructions in the Service Manual and the mini tach instruction sheet to route the tachometer wires Remove Handlebar Shroud 1 Follow instructions in the Service Manual to remove right saddlebag and right side cover NOTE When installing this kit on FLHR models the following adjust ment creates room between the inside of the windshield and the top of the nacelle 2 To create room between the inside of the windshield and the top of the nacelle a Remove windshield b Loosen but do not remov
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