How to remove my speedometer 04 883 - 2004 Harley Davidson XL 883 Sportster

To replace the speedometer drive gear on a vehicle with a part number 52068151, you will need to follow these steps:

1. Gather the necessary tools and supplies. You will need a new speedometer drive gear, a socket set, a ratchet, a torque wrench, and any other tools required to access the speedometer drive gear on your vehicle.
2. Locate the speedometer drive gear. The speedometer drive gear is typically located on the transmission or the transfer case of your vehicle. Refer to your vehicle's service manual for specific instructions on how to access the speedometer drive gear.
3. Remove the old speedometer drive gear. Use the socket set and ratchet to remove the bolts or screws that hold the old speedometer drive gear in place. Carefully remove the old speedometer drive gear from the transmission or transfer case.
4. Install the new speedometer drive gear. Place the new speedometer drive gear in the same position as the old one and secure it in place with the bolts or screws. Use the torque wrench to tighten the bolts or screws to the specified torque listed in the service manual.
5. Test the speedometer. After replacing the speedometer drive gear, test the speedometer to ensure it is functioning properly.

The speedometer cable mechanically drives the speedometer and the odometer

Remove the instrument cluster assembly. Refer to Instrument Cluster Replacement .
Unhook the speedometer cable from the heater case.
Remove the grommet from the bulkhead.
Feed the speedometer cable through the bulkhead.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Unscrew the speedometer cable (1) from either the transfer case or the transmission.
Remove the speedometer cable (1) from either the transfer case or the transmission.
Remove the speedometer cable (1) from the clamp.
Remove the speedometer cable (1) from the vehicle.

Removal Procedure

1. Remove the instrument cluster assembly. Refer to Instrument Cluster Replacement .
2. Unhook the speedometer cable from the heater case.
3. Remove the grommet from the bulkhead.
4. Feed the speedometer cable through the bulkhead.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Unscrew the speedometer cable (1) from either the transfer case or the transmission. Remove the speedometer cable (1) from either the transfer case or the transmission. Remove the speedometer cable (1) from the clamp. Remove the speedometer cable (1) from the vehicle.
Instrument Cluster Replacement
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
Disconnect the negative battery cable. Remove the hazard lamps switch by gently pulling the knob straight up. Remove the instrument cluster bezel from the instrument panel. Refer to Instrument Panel Cluster Trim Plate Bezel Replacement . Remove the 4 screws and pull the instrument cluster assembly forward from the instrument panel. Disconnect the 3 electrical connectors. Remove the speedometer cable at the speedometer head. Remove the instrument cluster assembly from the vehicle.
Remove the 5 screws (2) and the steering column upper and lower covers (1, 3).
Remove the 4 screws and the instrument cluster bezel from the vehicle.

The speedometer adapter is probably siezed in the aluminum case. Try working it loose with a can of Wd40 or equivelant, tap gently on it with a hammer to work the lubricant into the speedometer bore. Use a pair of vice grips to rotate and remove after you take the small clamp that is holding the adapter in

1. Remove seat.

2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.

3. Remove acorn nut and Phillips screw (with flat washer)
from instrument console.

4. Lay a clean shop towel on forward part of rear fender.
Lift the instrument console from fuel tank and lay upside
down on shop towel.

5.bend back the flexible metal clip to free the
harness conduit from the bottom of the console.

6. Remove the Speedometer Connector from the back of the speedometer.
Depress the external latches and use a rocking motion
to separate the pin and socket halves.

7. Gently pry the three latches upward
to release the lock ring from the back of the speedometer.

8. Turn the console over and remove the speedometer
from the top side.

9. Remove gasket from console speedometer bore.

Removing Speedometer Drive Gear

• Begin to remove the speedometer cable retainer and drive gear by cleaning off the top of the speedometer cable retainer.
• Then remove the hold-down screw that keeps the retainer in its bore.
• Carefully pull up on the speedometer cable, pulling the speedometer retainer and drive gear assembly from its bore.
• Unscrew the speedometer cable from the retainer and carefully remove both the cable and the old O-ring seal.

Installing Speedometer Drive Gear

• To reinstall the retainer, lightly grease the O-ring on the retainer and gently tap the retainer and gear assembly into its bore while lining the groove in the retainer with the screw hole in the side of the clutch housing case.
• Install the hold-down screw and tighten it in place.

Open front Trunk to access speedometer, remove cardboard cover and unplug electrical connections to speedometer one at a time and mark them so you can hook them back up in the same places, then un-screw the speedometer cable and remove the two nuts that hold speedometer to dashboard.

VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Drain the transmission oil.
3. Disconnect the vehicle speedometer sensor connector.
4. Remove the vehicle speedometer sensor.
5. Apply transmission oil to a new O-ring and install it on a new vehicle speedometer sensor.
6. Install the vehicle speedometer sensor. Tightening torque 69.5 - 95.4 inch lbs.
7. Connect the vehicle speedometer sensor connector.
8. Add the specified amount and type of transmission oil.
9. Connect the negative battery cable.

I remove two panel underneath the steering column. The first panel is removed using a 10 mm socket. The second panel is removed using a torx socket (can't remember the size). Removing these two panels gives you room to get to the clip on speedomter. Looking at the speedometer, you should see two rectangular holes on each side of the speedometer cover. I use a awl to push in the clip (you could use a screwdriver). Looking underneath the dash, you should be able to see the clip you are pushing on with the awl. I take my 2nd awl and put it behind the clip. I get the left side to release. One the speedometer cover releases, you can see the speedometer. You will see the 4 torx screws (t20) and two smaller clips holding the speedometer. All that is left is the wiring. (I take a sharpie pen and mark one of my wire locations on the speedometer. I am not sure what it does. It is a single wire.)

Replace the Speedometer Cable

1 - Remove the old speedometer cable from your car, first take off the doghouse and then the engine cover.

2 - Remove the screw underneath the dashboard and take down the steering column. This will give you access to the back of your speedometer.

3 - Take off the drive shaft bolt, and "O" ring, insert the speedometer cable through the firewall.

4 - Remove speedometer cable securing clamps from the engine compartment and on the transmission.

5 - Release the drive shaft nut from the "right angle" adapter (The nut is attached to the back of the transfer case).



Installing the Speedometer Cable

1 - Place the square end of the speedometer cable into the adapter and secure the drive shaft nut.

2 - Pull the speedometer cable through the firewall to the rear of the speedometer.

3 - Secure the "O" ring and attach the speedometer cable to the rear of the speedometer/odometer. It should be engaged in the speedometer's square hold. Tighten the drive shaft nut again.

4 - Replace the clamps that will secure the speedometer cable onto the transmission and in the engine compartment. Replace the engine cover.

5 - Drive your car slowly to be sure your speedometer is working properly. If it is, replace the doghouse. If you're stilling having problems, take the car to your mechanic.


Parts & tools -
Speedometer cable
Wrench
Screwdrivers

Good Luck.