Tip & How-To about 2004 Harley Davidson XL 883 Sportster

Installing Tacho on 2004 H-D Sportster 883cc Custom

If you have the above model Harley, you'll know it doesn't have a Tacho as standard, and that the factory-fitted risers prohibit installation on the handlebar centre. After selecting a suitable after-market indicator - there are plenty on J&P Cycle's website - you'll need to make or buy a simple, triangular bracket (polished stainless steel looks good), with a hole at each corner, picking up the two lower riser trim plate bolts. The third hole is for attaching the Tacho cannister and you'll probably need to drill a fourth hole to allow need cable routing - which will obviously require a rubber grommet. Or you can be clever and drill out the centre of your attachment bolt to achieve the same effect - don't forget to chamfer/smooth out the edges.
What is absolutely essential for the electrical connection of a tacho is a Crane Cams Tach Adaptor - p/n: 8-2050 - also available from J&P. On the 2004 XL883C, you'll need to follow the "Ground-Sensing" instructions, which are included with the adaptor. Remove seat & tank from the bike, run the Tacho wiring near the coil, disconnect coil plug at coil then cut that plug off (three wires), ensuring you have at least 3" of cable "Tail" going into the coil plug to attach additional wiring. Using a good-quality ratchet crimping tool and Red/Blue connectors, follow the connection table below:
a) Join Tacho Red wire (12v input to Tach), together with Tacho Blue wire (lighting), then add both to Blue wire from Tach Adaptor module. Join these (use a Blue sleeve crimp), to White/Black wire (12v supply from ignition switch), then rejoin White/Black wires.
b) Add long, Black wire from Tach module to Blue/Orange wire (one of the two 'Dual-Coil' switching lines from Ignition module to coil primary winding), then rejoin Blue/Orange wires as in a) above.
c) Add White wire from Tach module to Yellow/Blue wire (the other coil switching line), then rejoin Yellow/Blue as above.
d) Connect the Short, Black wire from tach module to Green wire from Tachometer (tape & tie back the short Grey wire to module).
e) Connect Black wire from Tacho to a good earth. I installed a large ring terminal with three "spare" earth wires under the head of a forward upper engine mounting bracket, but most of the Black wires on your Harley should be earth/ground wires - check first!
Now all you should have to do is wrap all your cable junctions with spiral wrapping or insulating tape, reconnect the coil plug, resecure any wiring looms/harnesses that you may have moved, refit tank & seat, then off you go - with shiny new tachometer telling you how fast your V-twin's turning.

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1 Answer

I'm fixing a 83 Harley-Davidson sportster. The last owner changed the handlebars and they are loose in the tripletree. what might be the problem?

If they are loose in the upper triple tree, you need to simply replace the riser bushings in the triple tree. Look under the triple tree and you'll see either two large bolts or two large nuts. If you take these off, you should see some rubber bushings that the risers go down through. If the bushings are worn or have gotten old and spongy, simply buy some new bushings and replace them. If the handle bars are loose in the handlebar clamp, take the clamp top off and see if the handle bars are knurled or have ridges cut in them. If not, they've put the wrong bars on the bike. You may can make a thin shim and put it around the bars and tighten it up a bit. If this doesn work, replace the clamp and risers.

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handle bar instalation riser bushains on a 1970 flh

The handlebar riser bushings are made of rubber sandwiched between to metal tubes. They are a loose press fit in the upper triple tree. Measure the depth of the old bushings, drive them out, and then drive the new ones in. If you don't want to go that route, you can get "change over" kits to change them to more like the later model bushings or to solid bushings that have no give at all. Check with a V-Twin dealer for the parts you need. http://www.vtwinmfg.com/webapp/wcs/stores/servlet/VTwinHome_10101_10102_-1

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May 17, 2011 | Harley Davidson FLHT Electra Glide...

1 Answer

how to tighting my handalebars on my flht i leaned on them to get off my bike and they moved down and i pulld them back up but now they move up and down thankyou if you can help me by telling me how to get to the bolts to thighten them back up

The earlier Electra Glides had a "riser cover" located on top of the headlight nachele right in the center. It had two screws holding it on. Remove the screws and you had access to the handlebar risers or clamps. The later models may not have this cover and you may have to remove the headlight nacele to get to the risers.

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tighten riser bolts or the two bolts holding the bars onto the riser.

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