INSTRUCTIONS - Harley
Contents
1. 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 2 See the FUEL LEVEL SENDER CARBURETED or FUEL INJECTED instructions for your model in the Service Manual Drain the fuel tank then remove the canopy and the attached fuel level sending unit PINNING Thoroughly clean and dry the canopy and fuel level sender assembly in a well ventilated area before drilling the assembly Failure to clean and dry the assembly in a well ventilated area could cause a fire resulting in death or serious injury 3 In a well ventilated area use an evaporative solvent such as a brake cleaner and compressed air to thor oughly clean the canopy and sending unit assembly 4 See FUEL LEVEL SENDER REMOVAL in the Service Manual to disassemble the fuel level sending unit from the support arm on the underside of the canopy Retain the 3 way connector from the old sending unit 5 For fuel injected models See the Service Parts illus tration Obtain the new fuel level sending unit 1 from the kit For carbureted models See the Service Parts illustra tion Obtain the new fuel level sending unit 1 from the kit Cut the black wire coming from the 2 way connector as close as possible to the splice inside the wire loom Pull the connector along with the attached orange wire and socket terminal2. View the fuel gauge while mov ing the float Awarninc After installing seat pull upward on front of seat to be 12 Install the canopy and attached fuel level sending unit sure it is in locked position While riding a loose seat using a new canopy gasket and ten new Torx screws can shift causing loss of control which could result in purchased separately death or serious injury 00070a 13 Fasten the wiring in the same way as the original instal lation with the new cable tie 4 from the kit Part No 75229 03 75241 03 Date 04 04 Service Part ay ervice ar S Fuel Gauge Sending Unit i02499b FLHR FLHRS FLHPI FLHPEI FLHRI FLHT FLHTC FLHRCI FLHRSI FLHTI FLHTCI FLHTCUI FLHTPI FLTRI Kit 75229 03 Fuel Level Sending Unit Kit FLHT FLTR shown Kit 75241 03 Fuel Level Sending Unit Kit FLHR FLHP Item Description Part No 1 Fuel gauge sending unit t Not sold separately 2 Blind rivet 8704 3 Screw truss head Torx K50 2 24 x 17 25 mm 1314 4 Cable strap 10065 FNOTE The sending units in these kits were designed for fuel injected models and must be modified to fit carbureted applications See illustration items A and B and Step 5 in the instructions Item Modification for carbureted applications A Cut the black wire as close as possible to the splice B Pull the orange wire and connector out of the loom and discard J03178 2 of 2
3. cMOTOR2 HARLEY DAVIDSON WY J03178 INSTRUCTIONS REV 04 22 2004 Kit Number 75229 03 and 75241 03 FUEL LEVEL SENDING UNIT KIT General Kit 75229 03 fits all 2003 and later e FLHT I Electra Glide FLHTC I Electra Glide Classic FLHTCUI Ultra Classic Electra Glide FLTRI Road Glide and FLHTPI model motorcycles Kit 75241 03 fits all 2003 and later e FLHR I Road King e FLHRS I Road King Custom e FLHRCI Road King Classic and e FLHPI and FLHPEI model motorcycles See the Service Parts illustration for kit contents Additional Parts Required The following items must also be replaced when performing this installation e 1 Canopy gasket part number 61402 02 e 10 Screws self sealing Torx part number 1311D e 1 O ring part number 11380 These items are available from any Harley Davidson dealer NOTE This instruction sheet references Service Manual informa tion A Service Manual for your model motorcycle is required for this installation and is available from any Harley Davidson Dealer Installation Removing the Old Sending Unit 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 Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable Retain all seat mounting hardware
4. out of the loom and discard it Installing the New Fuel Level Sending Unit 6 See FUEL LEVEL SENDER INSTALLATION in the Service Manual to assemble the new sending unit e For fuel injected models to the fuel pump housing using the screw 3 from the kit e For carbureted models to the support arm on the canopy using the blind rivet 2 from the kit 7 Insert the terminals from the new fuel level sender into the 3 way connector saved in Step 4 e Insert the black wire into chamber 3 marked s e e e Insert the yellow wire into chamber 2 marked e e For fuel injected models Insert the orange wire into chamber 1 marked e For carbureted models Chamber 1 marked e remains empty 8 Refer to CANOPY CONNECTOR O RING in the Service Manual to replace the existing O ring with a new O ring purchased separately 9 See the FUEL LEVEL SENDER CANOPY INSTALLA TION instructions for your model in the Service Manual Install the 3 way connector into the receptacle on the top of the canopy 1 of 2 10 Attach the spade connector to the tab on the underside 14 Fill the fuel tank with fuel and check for leaks of the canopy 15 Refer to the Service Manual and follow the instructions 11 Manually cycle the float assembly through a few full given to re attach the negative battery cable and install cycles from empty to full to ensure that the float con the seat tacts function correctly
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