-J03991 REV. 2006-05-12

TWO-INCH TACHOMETER KIT

GENERALKit Number

67564-05A

Models

This kit fits:

• 2004 and later FXD, FXDC, FXDX, and FXDWG

• 2004 and later Softail® (exept FLSTN)

• 2004 and later FLHR/C

• 2004 and later XL

• 2006 and later FXDB and FXD35

Kit Contents

See Figure 13 and Table 2.

Additional Tools Required

Installation of this kit will also require the use of special toolsand additional parts and supplies which are available from anyHarley-Davidson dealer.

Additional Parts Required

The two inch speedometer is designed to be used with aHarley-Davidson Genuine Motor Accessories two inch gaugehousing (sold separately) and a gauge bracket kit (sold sepa-rately).

2004 to 2006 XL, FXD and FXDC models equipped with a 2.0inch speedometer require additional purchase of harness, partnumber 67568-05.

NOTE

Do not use solvent based chemicals or waxes directly on theplastic or rubber components as they can affect the overallperformance and appearance of the plastic and rubber.

The rider's safety depends upon the correct installationof this kit. Use the appropriate service manual procedures.If the procedure is not within your capabilities or you donot have the correct tools, have a Harley-Davidson dealerperform the installation. Improper installation of this kitcould result in death or serious injury. (00333a)

NOTE

This instruction sheet references Service Manual information.A Service Manual for your model motorcycle is required forthis installation and is available from a Harley-Davidson dealer.

It is possible to overload your motorcycle's chargingsystem by adding too many electrical accessories. If yourcombined electrical accessories operating at any one timeconsume more electrical current than your vehicle'scharging system can produce, the electrical consumptioncan discharge the battery and cause vehicle electricalsystem damage. See a Harley-Davidson dealer for adviceabout the amount of current consumed by additionalelectrical accessories, or for necessary wiring changes.(00211b)

When installing any electrical accessory, be certain notto exceed the maximum amperage rating of the fuse orcircuit breaker protecting the affected circuit being modi-fied. Exceeding the maximum amperage can lead to elec-trical failures, which could result in death or serious injury.(00310a)

NOTE

This kit requires up to 100 milliamps additional current fromthe electrical system.

INSTALLATIONPrepare the Motorcycle

Gasoline can drain from quick-connect fitting whenremoving fuel line. Gasoline is extremely flammable andhighly explosive, which could result in death or seriousinjury. Wipe up spilled fuel immediately and dispose ofrags in a suitable manner. (00267a)

1. For EFI models: Follow the instructions found in theService Manual to purge the fuel supply of high pressuregasoline and remove the fuel supply line.

2. For all models: Follow the instructions found in the Ser-vice Manual to remove the seat and any side covers.

To prevent accidental vehicle start-up, which could causedeath or serious injury, disconnect negative (-) batterycable before proceeding. (00048a)

3. Disconnect the negative (-) battery cable from the battery.

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Excessive pressure can build in the fuel tank if vapor valveis not mounted vertically with long fitting to top. Leaksdue to excessive pressure can cause a fire or explosion,which could result in death or serious injury. (00265a)

4. For carbureted models: Turn the fuel supply valve toOFF. Remove the fuel line from the valve.

5. Follow the instructions in the Service Manual to removethe fuel tank.

6. For all models except FLHR: Follow the instructions inthe Service Manual to remove the headlamp housing.

7. For FLHR: Follow the instructions in the bracket kit toremove the handlebar shroud.

Install the Gauge Bracket

1. Follow the instructions in the bracket kit to install theselected gauge bracket.

2. Select from the two-inch tachometer kit, the rubber isola-tion gasket.

NOTELubricating the gasket with soap and water will make installationof the gasket easier.

3. Fit the perimeter groove in the rubber isolation gasket tothe inside edge of the bracket.

Tachometer Only: Route the Wire Harness

For installation with a two-inch speedometer, seeTachometer with Speedometer: Route the Wire Harnessor refer to the two-inch speedometer instructions.

1. Select the harness and install the grommet.

2. Route the harness through the gauge housing.

3. Route the two inch tachometer wire harness conduitthrough the forks and upper triple clamp, along the framebackbone to the area under the seat.

Tachometer Only: Black Lead to Ground

1. Use the wiring diagrams and the Service Manual, to locatethe ground for the year and model and route the two-inchtachometer harness ground (BK) lead to the ground.

For Dyna: See Figure 1. At either of the rear ground studsunder the fuse block.

For Softail: See Figure 2. Under the seat, near the fuseblock, on the left side of the vehicle.

For FLHR/C: See Figure 3. Under the seat directly in frontof the battery.

For XL Sportster:See Figure 4. On the engine casesbehind the starter.

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Figure 1. Dyna Ground

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Figure 2. Softail Ground

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Figure 3. FLHR Ground

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Figure 4. XL Ground

Tachometer Only: Route the Tachometer Lead(LGN/V) to Data Link Connector [91A]

1. Use the Service Manual to locate the data link connector[91A] for the model motorcycle. Remove the side panelsas required.

For Dyna: See Figure 5. At either of the rear ground studsunder the fuse block.

For Softail: See Figure 6. On the left side of the batteryin left frame rail.

For FLHR/C: See Figure 7. Under the seat directly in frontof the battery.

For XL: See Figure 8. On the engine cases behind thestarter.

2. Route the signal light green and violet lead (LGN/V) to thedata link.

3. Identify the signal (LGN/V) lead (cavity 3) from the datalink and cut the lead 1 1/2 inch from the connector.

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Figure 5. FXD Data Link

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Figure 6. Softail Data Link

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Figure 7. FLHR Data Link

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Figure 8. Data Link Connector [91A] (XL shown)

Tachometer Only: Route the Power (O/W) Lead toPower

1. For all models except XL: Route the power (O/W) lead tothe fuse block.

2. For the XL: Route the power (O/W) lead to the main wireharness along side the backbone.

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Tachometer Only: Adapt the Fuse Block to the PowerLead

1. For all models except XL: Access the fuse block andremove the cover.

2. For FLHR: See Figure 10. Select the power adapter fromthe kit and install the touring terminated end of the adapterinto the socket on the back of the fuse block marked P&AIGN.

For Dyna and Softail: Install the Dyna/Softail terminatedend of the power (O/W) lead from the adapter into thesocket on the back of the fuse block marked as OPEN.

3. Cut off the opposite terminal at the crimp.

NOTESee Figure 10. The power adapter will be spliced to thetachometer harness power lead (O/W). See .

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Figure 9. Fuse Block Cover with P&A IGN Mark

21

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1. Touring models terminal2. Dyna/Softail models terminal

Figure 10. Power Adapter

4. See Figure 11. Install the 2 Amp fuse in the P&A IGN(Softail/FLHR) or OPEN (FXD/FXDX/FXDWG) slot.

5. Install the fuse block and the cover.

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Figure 11. Socket for 2 Amp Fuse (2004 FXDWG shown)

Tachometer Only: Splice Power/Data Link Leads

1. Adjust the length of the tachometer harness leads to thepower adapter and the data link.

2. Strip 3/8 inch of insulation from the ends of the leads, thepower adapter and the data link.

3. See Figure 12. Splice the leads:

Splice the power lead to power adapter with a 1 into 1splice configuration.

Splice the LGN/V lead from the data link [91A] to thetachometer signal (LGN/V) lead with a 1 into 2 spliceconfiguration.

NOTE

Gently hold the seal connector from the kit in the red jaws ofthe Packard Crimp Tool (HD-38125-18). Feed the strippedlead(s) up to the wire stop inside the metal insert in one halfof the connector. Squeeze the tool to crimp the metal insert.The tool automatically opens when finished. Repeat for theother end of the connector to capture one or two striped leadsincluding, if required, the fuse block power adapter.

Be sure to follow manufacturer's instructions when usingthe UltraTorch UT-100 or any other radiant heating device.Failure to follow manufacturer's instructions can cause afire, which could result in death or serious injury. (00335a)

• Avoid directing the heat toward any fuel systemcomponent. Extreme heat can cause a fuel ignitionexplosion resulting in death or serious injury.

• Avoid directing heat toward any electrical systemcomponent other than the connectors on which heat-shrink work is being performed.

• Always keep hands away from tool tip area and heatshrink attachment.

4. Using the UltraTorch UT-100 (HD-39969) or other radiantheating device, heat the crimped splice form the center ofthe crimp out to each end until the sealant exudes out bothends of the connector and the tubing assumes a smoothcylindrical appearance.

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2

1is00135

1. 1 into 12. 1 into 2

Figure 12. Splice Configurations

Tachometer Only:Terminate the Ground Lead

1. If required, adjust the length of the ground lead (BK) fromthe tachometer harness and cut the lead to fit.

2. If necessary, strip 3/8 inch of insulation from end of theground (BK) lead.

3. Crimp the correct sized ring terminal on the bare wire ofthe ground lead.

For Dyna: 5/16 inch ring terminal.

For Softail and FLHR: 1/4 inch ring terminal.

For XL: 1/4 inch ring terminal.

4. Remove the main harness ground fastener and add thering terminal to the stud.

5. Install the ground fastener and tighten the torque specifi-cation found in the Service Manual.

Tachometer with 2-Inch Speedometer: Route theWire Harness

1. Follow the instructions in the two-inch speedometer kit toremove the original equipment speedometer and routethe speedometer wire harness from the speedometer kitto the main harness connector [108].

2. Route the terminated leads through the gauge housingand through the grommet. Follow the speedometer har-ness routing to the connector [108].

3. Separate the speedometer to tachometer pin and socketconnector [108] on the speedometer harness.

4. See Table 1. Using the 2.0 inch speedometer and tachharness purchased separately, match the terminated leadcolors to cavities 2, 3, and 6 in the pin connector half andfollow Service Manual instructions to insert the pins intothe connector.

Table 1. Connector [108] Cavity Numbers to Lead Colors

DescriptionLead ColorCavity

Tachometer signalLGN/V2

AccessoryO/W3

GroundBK6

Connect the Tachometer Harness to the Tachometer

1. Thread the two stand-offs from the gauge housing kit ontothe back of the tachometer.

2. Orient the gauge to the rider and slide the tachometer intothe isolation gasket in the gauge bracket.

NOTELubricating the isolation gasket with soap and water will makethe installation easier.

3. Fit the harness connector to the connector on the back ofthe tachometer.

4. Install the 2 flat head screws from the housing kit.Tightenthe flat head screws to 20-30 in-lbs (2.2-3.4 Nm).

Inspect and Secure the Wire Harness

1. Bounce motorcycle to look for pinch points between sus-pension components and tachometer wire harness.

2. Turn front forks lock to lock to look for pinch points.

3. Check for slack in wiring so that handlebar movement isnot restricted.

4. Check clearance from heat sources along harness.

5. Bundle the tachometer harness to the main wiring harnessalong frame backbone by using cable straps to supportwires so they do not chafe or contact hot or moving points.

Return Motorcycle to Service

1. Replace the fuel tank and attach fuel line or fittings.

2. Connect the negative (-) battery cable.

3. Install the maxi-fuse.

After installing seat, pull upward on seat to be sure it islocked in position. While riding, a loose seat can shiftcausing loss of control, which could result in death orserious injury. (00070b)

4. Install the side covers and the seat.

Test Installation

1. To test tachometer, turn ignition to ON. Start engine. Withengine idling, tachometer should indicate idle RPM (950to 1150 RPM).

2. Tachometer should respond to changes in throttle settings.

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SERVICE PARTS See Figure 13 and Table 2.

6 5

1

3

4

8

2

7

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Figure 13. Service Parts:Two-Inch Tachometer Kit

Table 2. Service Parts:Two-Inch Tachometer Kit

Part NumberDescription (Quantity)Item

54305-98Fuse, 2A "Mini"1

Not sold separatelyWiring harness, tachometer only2

11509Grommet3

70329-04Harness, fuse block adapter4

70586-93Sealed connector, 14-16 gauge5

9858Ring terminal, 1/4 inch6

9859Ring terminal, 5/16 inch7

10006Cable strap (10)8

67511-05Isolation gasket9

Not sold separatelyTachometer10

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