Professional Documents
Culture Documents
SPECIFICATIONS
9.1
EFI FUSES
TORQUE VALUES
Fuel Pump
15
Blue
Blade
ECM Power
15
Blue
Blade
EFI System
Relay
Fuel Pump
ECM Power
f1918x9x
Item
ft/in-lbs
Nm
15-20 ft-lbs
20-27 Nm
60-96 in-lbs
6.8-10.9 Nm
50-60 in-lbs
5.7-6.8 Nm
36-48 in-lbs
4.1-5.4 Nm
Crank position
sensor screw
90-120 in-lbs
10.2-13.6 Nm
25-35 in-lbs
2.8-4.0 Nm
120-180 in-lbs
13.6-20.3 Nm
15-20 ft-lbs
20-27 Nm
15-20 ft-lbs
20-27 Nm
18-24 in-lbs
2.0-2.7 Nm
25-35 in-lbs
2.8-4.0 Nm
22-26 ft-lbs
29.8-35.3 Nm
35-40 in-lbs
4.0-4.5 Nm
10-15 in-lbs
1.1-1.7 Nm
27-33 in-lbs
3.1-3.7 Nm
Intake flange
screws
96-144 in-lbs
10.9-16.3 Nm
60-80 in-lbs
6.8-9.0 Nm
Engine temperature
sensor
adapter
18 in-lbs
2.0 Nm
18 in-lbs
2.0 Nm
12 in-lbs
1.4 Nm
18 in-lbs
2.0 Nm
18 in-lbs
2.0 Nm
25 in-lbs
2.8 Nm
20-35 in-lbs
2.3-4.0 Nm
50-90 in-lbs
5.7-10.2 Nm
9-1
HOME
NOTES
9-2
HOME
9.2
GENERAL
Idle speed can only be set using the SCANALYZER (Part No.
HD-41325) or DIGITAL TECHNICIAN (Part No. HD-44750).
Use of the throttle stop screw will not permanently change
idle speed.
1.
2.
3.
4.
NOTE
For positive identification of CKP sensor
and oil pressure sending unit connectors,
note that CKP sensor has pin housing on
engine sensor harness side, while sending
unit has socket housing.
6
3
4,5
f1917x9x
1.
2.
3.
4.
5.
6.
7.
9-3
HOME
Fuel Pump
Fuse
REMOVAL
(15 Amp)
1.
2.
3.
4.
f1918x9x
ECM Power
Fuse
INSTALLATION
(15 Amp)
5.
6.
7.
Insert the diagnostic application cartridge into the Scanalyzer. During the next few seconds, the Scanalyzer
sequences through a series of screens that reflect a
power-on self test, the system copyright, and then an
attempt at communications with the ECM. Once communications is established, the diagnostic menu appears.
8.
9.
1.
2.
3.
4.
EFI FUSES
REMOVAL
1.
2.
NOTE
3.
4.
Pull fuses from slots in fuse block and inspect for damage. Replace fuse if the element is burned or broken.
Automotive type ATO fuses are used. See Figure 9-3.
9-4
NOTE
One extra 10 amp and 15 amp fuse are located in the system
fuse block under the left side cover. See Section 8.29 PREMIUM SOUND SYSTEM (FLHTC/U, FLTR), FUSE BLOCKS,
for more information.
INSTALLATION
1.
2.
HOME
3.
4.
f1942x9x
REMOVAL
1.
2.
3.
4.
1.
2.
3.
INSTALLATION
1.
2.
3.
4.
3.
4.
5.
SIREN CONNECTOR
EFI WIRE HARNESS
REMOVAL
1.
2.
3.
INSTALLATION
1.
2.
REMOVAL
1.
2.
3.
4.
5.
9-5
HOME
Front
6
5
1.
2.
3.
4.
5.
6.
3
f1939x9x
CAUTION
Damage to wires can result in electrical problems. Be
sure that rubber boot is present on threaded end of battery box TORX screw. Replace rubber boot if absent or
damaged.
6.
8321
NOTE
Draw all EFI wire harness connectors to right side of vehicle
as they are disconnected.
7.
8.
9.
10. Remove throttle position sensor and intake air temperature sensor connectors.
11. Moving to left side of vehicle, remove electrical connector from left side of ignition coil.
12. Pull back boot to reveal engine temperature sensor at
back of front cylinder. Pull external latch outward and
remove connector. Cut cable strap to release conduit
from horn bracket.
13. Returning to right side of vehicle, depress external latch
and remove 36-place Packard connector from ECM.
14. Note the data link connector (pin side of 4-place Deutsch) attached to the electrical bracket. See Figure 9-2.
Gently pull on connector to disengage from arms on
bracket.
9-6
8319
HOME
19. Note that harness conduit runs forward of the front battery box TORX screw. See upper frame of Figure 9-6.
Pull conduit to the rear of the screw, and then draw sensor connectors and conduit down right side of frame
backbone into battery box.
f1972x9x
Frame
Backbone
INSTALLATION
1
2
CAUTION
Damage to wires can result in electrical problems. Be
sure that rubber boot is present on threaded end of battery box TORX screw. Replace rubber boot if absent or
damaged.
1.
2.
3.
Loosely install new cable straps to secure EFI wire harness to right side of frame backbone and main wire harness bundle. See Figure 9-7.
4.
5.
6.
7.
Feed ignition coil and engine temperature sensor connectors to left side of vehicle, routing the first in front of
the top engine stabilizer link, the latter to the rear.
8.
9.
10. Mate pin and socket halves of oil pressure sending unit
and crankshaft position sensor connectors. To prevent
improper mating, crankshaft position sensor has pin
housing on engine sensor harness side, while the oil
pressure sending unit has a socket housing.
11. Route siren, oil pressure sending unit, and crankshaft
position sensor connectors and conduit on inboard side
of electrical bracket as shown in Figure 9-4.
Saddlebag
Guard
2 3
9-7
HOME
Electronic
Control Module
(ECM) [78B]
Data Link
[91A]
Main Wire
Harness [8B]
Fuel Pump
Fuse
EFI System
Relay
ECM Power
Fuse
Crankshaft Position
Sensor [79B]
Throttle
Position
Sensor [88B]
Oil Pressure
Sending
Unit [140A]
Rear
Injector
[85B]
Manifold Absolute
Pressure
Sensor [80B]
Intake Air
Temperature
Sensor [89B]
Ignition
Coil [83B]
Front
Injector
[84B]
Engine
Temperature
Sensor [90B]
Rubber
Boot
f1997x9x
Idle Air
Control [87B]
Figure 9-8. EFI Wire Harness Connectors
9-8
HOME
17. Tighten three cable straps securing EFI wire harness to
right side of frame backbone and main wire harness
bundle. Cut any excess cable strap material.
21. Install backplate and air cleaner. See Section 4.5 AIR
CLEANER, INSTALLATION.
1WARNING
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion producing personal injury and/or property
damage.
9-9
HOME
SENSORS
9.3
GENERAL
f1916x9x
ASSEMBLY,
MODULE
Crankshaft Position
Sensor [79]
ASSEMBLY,
Oil Pressure
Sending Unit [140]
CAUTION
Plastic tab protects connectors from dirt and moisture.
Do not pull plastic tab any further than necessary to free
connectors from cavity. Pulling tab too far will cause the
tab to crack or break.
6.
7.
8.
Feed engine sensor harness conduit and connectors forward through opening between frame downtube and
bottom front corner of battery box.
9.
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
2.
3.
4.
5.
9-10
HOME
15. Remove terminals from pin housing of 2-place MiniDeutsch connector.
f1692x8x
Socket Screw
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING PINS.
16. Obtain a length of strong flexible wire for use as
mechanics wire.
NOTE
Be sure that mechanics wire is of sufficient strength to pull
terminals and cable through conduit without breaking. Wire
length must also be long enough, so that free end is not lost
in conduit when pulled.
Convoluted
Tubing
O-Ring
INSTALLATION
f1629b8x
1.
2.
3.
4.
5.
6.
9-11
HOME
CAUTION
Chamber
Number
Red
Black
2
NOTE
8.
9.
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
2.
3.
14. Capture conduit in two cable clips on lower frame tube Tstuds. Snap cable clips closed.
4.
NOTE
5.
Slide a 3/4 inch deepwell socket over the sensor hex and
turn counter-clockwise to loosen. See Figure 9-12.
When sensor turns easily, pull out the deepwell socket
and remove sensor by hand.
The cable clips also capture the voltage regulator cables and
rear brake line.
15. Mate pin and socket halves of oil pressure sending unit
and crankshaft position sensor connectors. See Figure
9-9. To prevent improper mating of 2-place Mini-Deutsch
connectors, crankshaft position sensor has pin housing
on engine sensor harness side, while oil pressure sending unit has socket housing.
9-12
INSTALLATION
1.
HOME
Thermistor
Sensor
Body Hex
4.
5.
6.
Locking
Tab
f1699x9x
Electrical
Connector
3.
9-13
HOME
9.4
COMPLETE REMOVAL
FLHT/C/U/I, FLTRI
1WARNING
Fuel Tank
Canopy
Fuel Pump
Fuel Pressure Regulator
Fuel Filter Canister
Canopy
Fuel Filter
Canister
Fuel Level
Sender
and Float
Fuel Pressure
Regulator
In-tank Tubing
(Fuel Pressure Regulator
to Supply Fitting)
Fuel Pump
In-tank Tubing
Supply Fitting
(Check Valve)
9-14
f1969x9x
HOME
Fuel Pump
Fuse
(15 Amp)
a.
Remove the 15 amp fuel pump fuse. See Figure 914. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b.
c.
When the engine stalls, operate starter for 3 seconds to remove remaining fuel from fuel lines.
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
4.
5.
Carefully cut anchored cable strap securing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
6.
7.
8.
9.
Remove filler cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall filler
cap.
f1918x9x
1WARNING
Gasoline will drain from the crossover hose when disconnected from the fuel tank. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable
manner. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
death or serious injury.
CAUTION
Do not kink crossover hose or crimp shut using pliers or
similar tool. Damage to the rigid inner lining will occur.
1.
Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D.
Insert bolt in one end of hose and install hose clamp to
ensure that end is securely plugged. Using a side cutters, cut
clamp from one end of crossover hose beneath fuel tank.
Quickly replace crossover hose on fuel tank fitting with open
end of short hose while directing flow of gasoline from free
end of crossover hose into suitable container.
2.
1WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
supply line is disconnected. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury.
3.
10. At top of canopy, depress button on socket side of 3place Mini-Deutsch connector to release fuel tank harness.
11. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
1WARNING
A small amount of gasoline may drain from the fuel supply line when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
12. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-15.
9-15
HOME
7.
8.
f2021x9x
Fuel
Tank
Chrome
Sleeve
1WARNING
A small amount of gasoline may drain from the fuel supply line when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
1WARNING
13. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
9.
NOTE
The fuel tank mounting bolts have both an internal TORX
recess and an external hex, which allows them to be
removed with either a T40 TORX bit or a 1/2 inch open end/
box wrench. Use of the external hex allows the front mounting bolts to be removed without having to loosen or remove
the fairing lowers, if installed.
14. Remove fuel tank from vehicle.
FLHR/C/I
1.
See Section 9.4 FUEL TANK (FUEL INJECTED), COMPLETE REMOVAL, FLHT/C/U/I, FLTRI, steps 1-4.
2.
Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
3.
10. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
11. Remove fuel tank from vehicle.
INSTALLATION
(AFTER COMPLETE REMOVAL)
FLHT/C/U/I, FLTRI
CAUTION
Exercise caution to avoid pinching the wiring harness
between the fuel tank and vehicle frame. Wire damage
may result in electrical problems.
1.
2.
Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank (after removing
temporary plug). Crimp clamp.
3.
5.
4.
6.
CAUTION
When removing instrument console, exercise caution to
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
4.
9-16
HOME
5.
f2007x9x
Fuel
Tank
Console
Pod
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
Fuel Pump,
Fuel Level
Sender Conduit
Main
Harness
Bundle
6.
Fuel Vapor
Vent Tube
Fuel
Overflow
Hose
Console
Pod Conduit
Tighten fuel tank front mounting bolts to 15-20 ft-lbs (2027 Nm).
Anchored
Cable Strap
Main
Harness
Bundle
FLHTCUI
f1739b9x
Fuel
Tank
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
7.
8.
Mate pin and socket halves of 3-place Mini-Deutsch connector to install fuel tank harness at top of canopy.
9.
Console
11. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
Fuel Pump,
Fuel Level
Sender Conduit
Fuel Vapor
Vent Tube
Fuel
Overflow
Hose
12. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube. See Figure 9-16. Cut any excess cable strap material.
NOTE
Main
Harness
Bundle
Main
Harness
Bundle
FLHT/C/I, FLTRI
Figure 9-16. Console Pod Cable/Hose Routing
(Top View)
9-17
HOME
FLHR/C/I
1.
2.
Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank (after removing
temporary plug). Crimp clamp.
3.
PARTIAL REMOVAL
4.
FLHT/C/U/I, FLTRI
5.
Tighten fuel tank front mounting bolts to 15-20 ft-lbs (2027 Nm).
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
6.
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
7.
8.
Mate pin and socket halves of 3-place Mini-Deutsch connector to connect main harness at top of canopy. Bend
flexible clamp to capture conduit.
9.
9-18
1WARNING
Gasoline is extremely flammable and highly explosive.
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Inadequate safety
precautions could result in death or serious injury.
1.
1WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
supply line is disconnected. Inadequate safety precautions could result in death or serious injury.
2.
Remove the 15 amp fuel pump fuse. See Figure 914. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b.
c.
When the engine stalls, operate starter for 3 seconds to remove remaining fuel from fuel lines.
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
3.
4.
Carefully cut anchored cable strap securing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
5.
HOME
6.
7.
8.
Remove filler cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall filler
cap.
9.
At top of canopy, depress button on socket side of 3place Mini-Deutsch connector to release fuel tank harness.
10. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
1WARNING
A small amount of gasoline may drain from the fuel supply line when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
1WARNING
2.
Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
3.
5.
6.
7.
8.
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
11. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-15.
12. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
1WARNING
A small amount of gasoline may drain from the fuel supply line when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
NOTE
The fuel tank mounting bolts have both an internal TORX
recess and an external hex, which allows them to be
removed with either a T40 TORX bit or a 1/2 inch open end/
box wrench. Use of the external hex allows the front mounting bolts to be removed without having to loosen or remove
the fairing lowers, if installed.
13. Raise the fuel tank approximately 2 inches. Move the
fuel tank crossover hose to the rear of the ignition coil,
so that the tank can be raised an additional 2-3 inches.
Move fuel tank straight back and rest on frame backbone.
14. Obtain several 1 x 2 inch wooden blocks. Raise front and
rear of fuel tank off the frame backbone by placing
blocks in tunnel at bottom of tank.
FLHR/C/I
1.
See Section 9.4 FUEL TANK (FUEL INJECTED), PARTIAL REMOVAL, FLHT/C/U/I, FLTRI, steps 1-3.
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
9.
10. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
11. Raise the fuel tank approximately 2 inches. Move the
fuel tank crossover hose to the rear of the ignition coil,
so that the tank can be raised an additional 2-3 inches.
Move fuel tank straight back and rest on frame backbone.
9-19
HOME
12. Obtain several 1 x 2 inch wooden blocks. Raise front and
rear of fuel tank off the frame backbone by placing
blocks in tunnel at bottom of tank.
INSTALLATION
(AFTER PARTIAL REMOVAL)
FLHT/C/U/I, FLTRI
1.
11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube. Cut any excess cable strap material. See Figure 916.
NOTE
Route fuel overflow hose inboard of wire bundles on right
side of frame, but do not capture in cable straps.
12. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
13. Install the 15 amp fuel pump fuse. See Figure 9-14. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
2.
3.
FLHR/C/I
4.
Tighten fuel tank front mounting bolts to 15-20 ft-lbs (2027 Nm).
1.
2.
3.
4.
Tighten fuel tank front mounting bolts to 15-20 ft-lbs (2027 Nm).
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
5.
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
6.
7.
Mate pin and socket halves of 3-place Mini-Deutsch connector to install fuel tank harness at top of canopy.
8.
9.
10. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
9-20
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
5.
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
6.
7.
Mate pin and socket halves of 3-place Mini-Deutsch connector to connect main harness at top of canopy. Bend
flexible clamp to capture conduit.
HOME
8.
9.
1WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
supply line is disconnected. Inadequate safety precautions could result in death or serious injury.
3.
11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material. See Figure 9-16.
12. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
13. Install the 15 amp fuel pump fuse. See Figure 9-14. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
14. Install seat. See Section 2.22 SEAT, INSTALLATION.
CONSOLE POD/CANOPY
1.
2.
b.
c.
When the engine stalls, operate starter for 3 seconds to remove remaining fuel from fuel lines.
4.
5.
Carefully cut anchored cable strap securing main harness bundle, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
6.
7.
8.
9.
Remove filler cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall filler
cap.
1WARNING
Remove the 15 amp fuel pump fuse. See Figure 914. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
REMOVAL
CAUTION
a.
1WARNING
FLHT/C/U/I, FLTRI
Gasoline will drain from the crossover hose when disconnected from the fuel tank. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable
manner. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
death or serious injury.
10. At top of canopy, depress button on 3-place Mini-Deutsch connector to release fuel tank harness.
11. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
12. Using a T20 TORX bit, remove ten screws around the
outer edge of the canopy. Discard screws.
13. Raise canopy slightly to access top fitting (inlet port) at
back of fuel pressure regulator. Using a side cutters, cut
hose clamp and remove convoluted tube. Exercise caution to avoid cutting or damaging tube or dropping
pieces of cut clamp into fuel tank. See Figure 9-17.
9-21
HOME
3.
f1955x9x
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
4.
Convoluted
Tube
1WARNING
Figure 9-17. Raise Canopy and Remove Tube
(FLHT/C/U/I, FLTRI)
14. Remove canopy from fuel tank (with attached fuel pressure regulator, fuel filter canister, fuel pump and fuel
level sender).
A spring-loaded hinge on the fuel pump bracket facilitates removal of the assembly. For best results, press
down on top of fuel pump with index finger or end of
screwdriver, and after raising canopy slightly, rotate on
hinge in a counterclockwise direction. When canopy is at
Sealing
Device
f1963x9x
INSTALLATION
1.
CAUTION
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will
result in erroneous gauge readings.
2.
9-22
10
f2011x9x
HOME
5.
While pushing down on the canopy, align holes in canopy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
Figure 9-18.
6.
7.
Mate pin and socket halves of 3-place Mini-Deutsch connector to install fuel tank harness at top of canopy.
8.
9.
f1957x9x
f1956x9x
10. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube. See Figure 9-16. Cut excess cable strap material.
12. Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank. Crimp clamp.
13. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
14. Install the 15 amp fuel pump fuse. See Figure 9-14. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
INSTRUMENT CONSOLE/CANOPY
CAUTION
Do not kink crossover hose or crimp shut using pliers or
similar tool. Damage to the rigid inner lining will occur.
FLHR/C/I
1.
REMOVAL
1WARNING
Gasoline will drain from the crossover hose when disconnected from the fuel tank. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable
manner. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
death or serious injury.
2.
9-23
HOME
1WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
supply line is disconnected. Inadequate safety precautions could result in death or serious injury.
3.
Remove the 15 amp fuel pump fuse. See Figure 914. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b.
c.
When the engine stalls, operate starter for 3 seconds to remove remaining fuel from fuel lines.
13. Remove canopy from fuel tank (with attached fuel pressure regulator, fuel filter canister, fuel pump and fuel
level sender).
A spring-loaded hinge on the fuel pump bracket facilitates removal of the assembly. For best results, press
down on top of fuel pump with index finger or end of
screwdriver, and after raising canopy slightly, rotate on
hinge in a counterclockwise direction. When canopy is at
a 45 angle to top of fuel tank, carefully pull assembly
from left side lobe of fuel tank. See Figure 9-19.
14. Remove and discard canopy gasket. Verify that sealing
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
INSTALLATION
1.
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
4.
5.
Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
6.
CAUTION
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will
result in erroneous gauge readings.
2.
3.
CAUTION
When removing instrument console, exercise caution to
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
7.
8.
9.
9-24
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
4.
1WARNING
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity
resulting in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
HOME
NOTE
Check canopy screws for proper sealing devices. Screws
must have a bonded seal on underside of head. Replace
screws if seal is missing or damaged. See Figure 9-18.
5.
While pushing down on the canopy, align holes in canopy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
Figure 9-18.
6.
7.
Mate pin and socket halves of 3-place Mini-Deutsch connector to connect main harness at top of canopy. Bend
flexible clamp to capture conduit.
8.
9.
10. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material.
f1940x9x
11. Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank. Crimp clamp.
12. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
13. Install the 15 amp fuel pump fuse. See Figure 9-14. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
14. Install seat. See Section 2.22 SEAT, INSTALLATION.
f1945x9x
REMOVAL
1.
2.
Pull wireform to release from slots on fuel filter canister bracket. See A of Figure 9-20.
b.
c.
f1944x9x
9-25
HOME
3.
Using a side cutters, cut hose clamp and remove convoluted tube from inlet port at side of fuel filter canister.
Exercise caution to avoid cutting or damaging tube. Discard fuel filter canister.
INSTALLATION
CAUTION
Do not replace tubes inside of fuel tank with ordinary
bulk hose. All internal lines must be replaced with the
special original equipment convoluted nylon tubes. Bulk
hose will degrade when immersed in gasoline (particularly stale gasoline), resulting in contamination of the
fuel supply. Use of contaminated fuel will cause starting
and driveability problems and possible vehicle damage.
1.
2.
3.
b.
c.
f1943x9x
Housing
O-Ring
f1931x9x
3.
4.
Remove fuel pressure regulator from housing. To overcome the resistance of two O-rings, insert blade of small
screwdriver into gap between regulator and housing and
gently pry regulator out. See Figure 9-22.
5.
INSTALLATION
1.
2.
3.
Fit fuel pressure regulator assembly into canopy weldment engaging arms in catches. See Figure 9-21.
REMOVAL
1.
2.
9-26
HOME
4.
5.
INSTALLATION
1.
2.
FUEL PUMP
REMOVAL
CAUTION
1.
2.
3.
4.
Remove T15 TORX screw and pull fuel level sender from
post on fuel pump bracket.
5.
4.
5.
6.
Be absolutely certain fuel pump is faulty before removing hinge from support arm. Hinge is damaged during
removal and requires replacement of the fuel pump and
bracket assembly.
6.
Insert flat tip screwdriver at location shown in Figure 923. Carefully crack plastic webbing at top of hinge and
remove from support arm. Discard fuel pump and
bracket assembly.
7.
Inspect the condition of the fuel pump wiring. If the wiring needs to be replaced, see FUEL PUMP/FUEL
LEVEL SENDER WIRING on this page.
8399
Screwdriver
NOTE
Damaged fuel pump and/or fuel level sender wiring requires
replacement of the fuel level sender unit. See FUEL LEVEL
SENDER on this page.
9-27
HOME
7.
f1946x9x
NOTE
For additional clearance, pull wireform to release from slots
on fuel filter canister bracket, and then use hinge to swing
wireform out of the way. Move canister bracket forward to disengage tab from slot on canopy weldment. Remove socket
terminal from spade contact on connector clip.
Push
Pull
a.
b.
c.
d.
INSTALLATION
1.
f1930x9x
2.
3.
4.
5.
6.
Remove T15 TORX screw and pull fuel level sender from
post on fuel pump bracket.
9-28
Chamber
Wire Color
Function
Orange
Pump Power
Yellow
Sender Output
Black
Ground
NOTE
A series of dots are molded into the wire end of the block to
indicate wire location, one dot indicating chamber 1, two dots
chamber 2, three dots chamber 3. (Wire location numbers
are also stamped below the terminals inside the Mini-Deutch
pin housing.)
2.
Gently tug on wires to verify that they will not back out of
wire block.
3.
4.
HOME
5.
REMOVAL
1.
6.
7.
Install new cable strap capturing wiring at bottom of support arm. Cut any excess cable strap material.
1WARNING
8.
A small amount of gasoline may drain from the fuel supply line when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
CANOPY CONNECTOR/O-RING
REMOVAL
1.
2.
3.
4.
5.
INSTALLATION
1.
2.
Fit connector body into hole at top of canopy. At underside of canopy, install connector clip engaging slots in
connector body.
3.
Insert wire block back into connector body until tabs lock
in windows. One corner of wire block and connector
body is square to prevent improper installation.
4.
5.
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
2.
1WARNING
A small amount of gasoline may drain from the fuel tank
when the quick-connect fitting is removed. Thoroughly
wipe up any spilled fuel immediately. Dispose of rags in
a suitable manner. Inadequate safety precautions could
result in death or serious injury.
3.
INSTALLATION
CAUTION
Carefully inspect convoluted tube for cuts, tears, holes
or other damage. Replace tube (with attached quick-connect fitting) if any damage is found. Even the smallest
hole can cause a reduction in fuel pressure.
1.
NOTE
The in-tank check valve is housed in the quick-connect fitting.
The check valve prevents the fuel tank from draining when
the external supply line is disconnected.
2.
9-29
HOME
Convoluted
Tube
O-Ring
Body Hex
Chrome Sleeve
f2048x9x
3.
1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
4.
9-30
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
5.