Harley Davidson 2011 Touring Models. Service Manual — page 36

2011 Touring Service: Fuel System 4-3

4.3

ELECTRONIC FUEL INJECTION (EFI)

TROUBLESHOOTING

See the electrical diagnostic manual for troubleshooting and
diagnostic information.

4-4 2011 Touring Service: Fuel System

4.4

AIR CLEANER ASSEMBLY

REMOVAL

See

Figure 4-1

. Remove cover screw (1) from air cleaner

cover (3). Remove air cleaner cover with rubber seal (4).

Remove three T27 TORX screws (5) to release cover
bracket (6) from filter element (7).

Remove filter element pulling two breather tubes (9) from
holes on inboard side.

Remove gasket (8) from sleeve on inboard side of filter
element. Discard gasket.

Remove breather tubes from fittings on two cylinder head
breather bolts (10).

Remove two cylinder head breather bolts from backplate
(11).

Remove backplate from cylinder heads.

Remove seal ring (12) from groove on inboard side of
backplate. Discard seal ring.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

Inspect filter element. See

1.7 AIR CLEANER AND

EXHAUST SYSTEM

. Replace the filter element if damaged

or if filter media cannot be adequately cleaned.

2011 Touring Service: Fuel System 4-5

sm04085

Filter element

Cover screw

Cover trim

Gasket

Breather tube (2)

Air cleaner cover

10.

Rubber seal

Breather bolt (2)

11.

Backplate

T27 Torx screw (3)

12.

Cover bracket

Seal ring

Figure 4-1. Air Cleaner Assembly

INSTALLATION

See

Figure 4-1

. With the nubs contacting the ring groove

walls, install seal ring (12) on inboard side of backplate
(11).

Align holes in backplate with those in cylinder heads and
install cylinder head breather bolts (10). Alternately tighten
bolts to 22-24 ft-lbs (29.8-32.5 Nm).

Slide

new

gasket (8) over sleeve on inboard side of filter

element.

Insert breather tubes about 0.25 in (6.4 mm) into holes on
inboard side of filter element (7).

Install breather tubes onto fittings of two cylinder head
breather bolts.

NOTE

Air cleaner mounting without installation of the breather tubes
allows crankcase vapors to be vented into the atmosphere in
violation of legal emissions standards.

Place filter element onto backplate with the flat side down.

Align holes in cover bracket (6) with those in filter element
and start three T27 TORX screws (5). Alternately tighten
screws to 40-60

in-lbs

(4.5-6.8 Nm).

4-6 2011 Touring Service: Fuel System

Verify that rubber seal (4) is properly seated around peri-
meter of air cleaner cover (3).

Fit air cleaner cover into backplate. Apply a small dab of
LOCTITE MEDIUM STRENGTH THREADLOCKER 243
(BLUE) to threads of cover screw (1). Install screw and
tighten to 36-60

in-lbs

(4.1-6.8 Nm).

2011 Touring Service: Fuel System 4-7

4.5

FUEL TANK

REMOVAL

NOTE

The fuel tank can be removed without draining. However,
draining is necessary whenever the fuel tank or internal com-
ponents are serviced.

Purge and Disconnect Fuel Line

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

NOTE

The gasoline in the fuel supply line is under high pressure: 58
psi (400 kPA). To avoid an uncontrolled discharge or spray of
gasoline, always purge the line before disconnecting.

Remove left side saddlebag. See

2.26 SADDLEBAGS

Remove left side cover.

See

Figure 4-2

. Remove 15 amp fuel pump fuse.

Start the engine and allow the motorcycle to run until
engine stalls. Operate starter an additional 3 seconds to
remove remaining fuel from fuel supply line.

Remove main fuse.

Install 15 amp fuel pump fuse.

See

Figure 4-3

. Pull up on chrome sleeve of quick-connect

fitting and pull down on fuel supply line fitting to disconnect.

Remove Tank

Remove seat. See

Remove console from tank and lay out of the way.

Carefully pry fuel vapor vent tube from vapor valve fitting
on top plate.

Remove fuel level sender/fuel pump connector [141], 4-
place Delphi.

Road King models:

Gently pull on convoluted tubing to

draw fuel gauge connector out of tunnel at front of fuel
tank. Disconnect connector.

Gasoline can drain from the fuel line when disconnected
from fuel tank. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
suitable manner. (00260a)

Remove rubber caps to reveal two front fuel tank screws.
Remove screws.

Remove two screws to release rear tank bracket from
frame backbone.

Remove fuel tank from motorcycle.

sm05910

1. Fuel pump fuse
2. Main fuse

Figure 4-2. Fuse Blocks

sm04502

1. Quick connect fitting (chrome sleeve)
2. Fuel supply line fitting

Figure 4-3. Fuel Tank (Left Side View)

INSTALLATION

Place fuel tank onto frame backbone and start front fuel
tank fasteners.

Secure rear fuel tank bracket to frame backbone. Tighten
screws to 15-20 ft-lbs (20.3-27.1 Nm). Install plastic trim
cover over bracket.

Tighten front fuel tank screws to 15-20 ft-lbs (20.3-27.1
Nm). Install rubber caps over screws. Note that the left
and right caps are not interchangeable.

4-8 2011 Touring Service: Fuel System

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

Connect quick-connect fitting to fuel tank. While pushing
up on bottom of fitting, pull down on chrome sleeve. Tug
on fuel line fitting to verify that it is locked in position.

Road King models:

Mate fuel gauge connector. Feed

connector into tunnel at front of fuel tank.

See

Figure 4-4

. Connect fuel vapor vent tube to vapor

valve fitting (1) on top plate.

If equipped, connect overflow hose (2) to top plate and
route along inner downtube as shown. Secure to brake
line with cable strap (3). Do not over-tighten cable strap.

Install fuel level sender/fuel pump connector [141], 4-place
Delphi. For best clearance with cam ring, tilt connector at
35 degree angle before installation.

Install console. Tighten fasteners to 36-60

in-lbs

(4.1-6.8

Nm).

10. Install seat. See

11. Install main fuse, left side cover and saddlebag.

EVAPORATIVE EMISSIONS TUBE: NON-CA
MODELS

Removal

Remove seat. See

Remove fuel tank console:

Remove screws to release front and rear of console
from fuel tank.

Lay a clean shop towel on forward part of rear fender.

FLHR/C:

Remove console and lay upside down on

shop towel.

FLHX, FLHTC/U, FLHTK, FLTRX, FLTRU:

Remove

filler cap. Remove console and lay upside down on
shop towel. Install filler cap.

See

Figure 4-4

. Remove vapor tube from fitting (1) on fuel

tank top plate.

Remove two cable straps (4) securing tube to rear frame
downtube.

Remove tube from motorcycle.

Inspect for deterioration, chaffing, or other damage.
Replace as necessary.

sm05938a

1. Fuel vapor vent tube fitting
2. Overflow hose
3. Cable strap
4. Cable strap

Figure 4-4. Non-California Evaporative System

Installation

See

Figure 4-4

. Route tube down along inner side of rear

left downtube. Install two cable straps (4) to secure to
frame.

Route line along center of fuel tank and connect to fitting
(1) on fuel tank top plate.

Install fuel tank console:

FLHR/C:

Position console on fuel tank.

FLHX, FLHTC/U, FLHTK, FLTRX, FLTRU:

Remove

filler cap and position console on fuel tank. Install filler
cap.

Verify harnesses and vent tube are not pinched.

Install screws to fasten front and rear of console to
fuel tank.

Tighten screws to 36-60

in-lbs

(4.1-6.8 Nm).

Install seat. See

FUEL SUPPLY CHECK VALVE/TUBE

Removal

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.

2011 Touring Service: Fuel System 4-9

Remove top plate. See

Pull up on chrome sleeve and pull down on fuel supply
line fitting to disconnect fuel line from tank.

See

Figure 4-5

. Loosen quick-connect fitting.

Remove the fitting and fuel supply tube from fuel tank.

Installation

NOTE

Carefully inspect fuel supply tube for cuts, tears, holes or other
damage. Replace tube (and quick-connect fitting assembly) if
any damage is found.

See

Figure 4-6

. Apply a very light film of clean engine oil

new

O-ring. Slide O-ring into groove of quick-connect

fitting.

Feeding fuel supply tube through hole at bottom of fuel
tank, hand thread quick-connect fitting into bore.

Tighten fitting to 22-26 ft-lbs (29.8-35.3 Nm).

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

Connect quick-connect fitting to fuel tank. While pushing
up on bottom of fitting, pull down on chrome sleeve. Tug
on fuel line fitting to verify that it is locked in position.

Install top plate. See

sm04504

Figure 4-5. Engage Hex on Quick-Connect Fitting

xx00000

1. Chrome sleeve
2. Body hex
3. O-ring

Figure 4-6. Fuel Supply Check Valve/Tube

4-10 2011 Touring Service: Fuel System

4.6

FUEL TANK TOP PLATE

REMOVAL

TOOL NAME

PART NUMBER

CAM RING REMOVER/INSTALLER

HD-48646

NOTE

The gasoline in the fuel supply line is under high pressure (58
psi (400 kPa). To avoid an uncontrolled discharge or spray of
gasoline, always purge the line before top plate removal.

Relieve pressure from fuel system. See

4.5 FUEL TANK,

Removal

Drain fuel from tank. Use a common pump or siphon and
an approved gasoline storage container of sufficient
capacity.

Remove seat. See

Remove console from tank and lay out of the way.

See

Figure 4-7

. Remove cam ring using CAM RING

REMOVER/INSTALLER (Part No. HD-48646) and raise
top plate.

NOTE

See

Figure 4-8

. Always hold on to both the Cam Ring

Remover/Installer and ratchet to prevent unexpected separation
resulting in possible damage to the fuel tank.

Remove connector at bottom of top plate. A small screw-
driver may help with removal.

See

Figure 4-9

. Disconnect ground wire spade terminal

from slot of top plate.

See

Figure 4-10

. Press tabs on fuel line retainers (3) to

remove lines from fittings on fuel filter shell.

If top plate replacement is necessary, remove fuel filter
shell. See

4.7 FUEL FILTER

sm04067

Figure 4-7. Cam Ring Remover/Installer (HD-48646)

sm04098

Figure 4-8. Hold Both Tool and Ratchet During Handling

sm04068

Figure 4-9. Remove Ground Wire Spade Terminal From

Top Plate

2011 Touring Service: Fuel System 4-11

sm04187

1. With Fuel Filter Shell
2. Without Fuel Filter Shell
3. Fuel line retainers

Figure 4-10. Top Plate Assembly

INSTALLATION

TOOL NAME

PART NUMBER

CAM RING REMOVER/INSTALLER

HD-48646

If installing a

new

top plate, first install fuel filter shell. See

4.7 FUEL FILTER

Inspect seal ring at bottom of top plate for cuts, tears or
signs of deterioration. If necessary, install

new

seal ring

with the nubs contacting the ring groove walls.

See

Figure 4-10

. Verify retainers (3) are secure on fuel

filter fittings, and that they are not damaged. Note that
retainers are of different sizes to prevent improper
assembly.

Aligning latches and push tubes onto fittings of fuel filter
shell until an audible click is heard. Pull on tubes to verify
they are attached securely.

Install connector at bottom of top plate.

Route ground wire (from top plate connector) along inboard
side of vapor valve and install spade terminal into slot in
top plate.

Install fuel tank top plate engaging index tab in slot at front
of fuel tank collar.

See

Figure 4-11

. Install cam ring over fuel tank top plate

with the TOP stamp up.

Engage CAM RING REMOVER/INSTALLER (Part No. HD-
48646) in top plate. Push down on tool and rotate in a
clockwise direction until each of four index tabs begin to
engage slots in fuel tank collar.

10. Install ratchet and rotate until cam ring is fully installed.

NOTE

See

Figure 4-8

. Always hold onto both the Cam Ring

Remover/Installer and ratchet during handling or separation
of parts may cause one to be dropped, possibly resulting in
hard contact with fuel tank.

11. Install console. Tighten fasteners to 36-60

in-lbs

(4.1-6.8

Nm).

12. Install seat. See

Wipe up spilled fuel and dispose of rags in a suitable
manner. An open spark around gasoline could cause a
fire or explosion, resulting in death or serious injury.
(00518b)

13. Fill fuel tank. Carefully inspect for leaks. Start engine and

repeat inspection.

sm04196

Figure 4-11. Cam Ring Stamp

4-12 2011 Touring Service: Fuel System

4.7

FUEL FILTER

REMOVAL

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

Remove top plate. See

Locate ground wire spade terminal in slot of fuel filter shell.
Insert tip of small flat blade screwdriver through window
to press tang, and then pull terminal from slot. See

Figure 4-12

Gently raise locking arm and pull U-clip from holes in fuel
filter shell.

Remove fuel filter shell from end cap.

Remove O-ring and filter from fuel filter shell. See

Figure 4-13

sm04033

Figure 4-12. Remove Ground Wire Spade Terminal From

Fuel Filter Shell

sm04035

1. Filter shell
2. U-clip
3. O-ring
4. Filter

Figure 4-13. Fuel Filter Assembly

INSTALLATION

Install

new

filter in fuel filter shell.

Seat O-ring on counterbore at top of filter.

Install fuel filter shell over end cap, so that slot in fuel filter
shell engages index pin on end cap.

Holding parts together, slide U-clip through holes on
locking arm side of fuel filter shell. Push U-clip until ends
exit holes on opposite side. Retract U-clip until contact is
made with step in locking arm.

Route ground wire (from top plate TORX screw) around
index pin side of end cap and install spade terminal into
slot in fuel filter shell. Gently tug on wire to verify that ter-
minal is locked.

NOTE

If terminal does not lock, use a thin flat blade, like that on a
hobby knife, to bend tang outward slightly away from terminal
body.

Install top plate. See

2011 Touring Service: Fuel System 4-13

4.8

FUEL PRESSURE REGULATOR

REMOVAL

Remove top plate. See

See

Figure 4-14

. Remove ground wire spade terminal

from slot of fuel filter shell.

Remove spring clip from fuel pressure regulator. For best
results, free one side first and then the other.

See

Figure 4-15

. Remove fuel pressure regulator, regulator

seat, large O-ring, screen and small O-ring.

sm04033

Figure 4-14. Remove Ground Wire Spade Terminal From

Fuel Filter Shell

sm04032

1. Spring clip
2. Fuel pressure regulator
3. Regulator seat
4. Large O-ring
5. Screen
6. Small O-ring

Figure 4-15. Fuel Pressure Regulator Assembly

INSTALLATION

See

Figure 4-15

. Insert small O-ring at top of pressure

port bore.

Install screen at top of pressure regulator bore, so that
sleeve on ID faces small O-ring. Install regulator seat to
evenly press screen into bore. Remove regulator seat.

Install large O-ring at top of screen.

Install regulator seat and fuel pressure regulator.

Install spring clip, so that indented sides engage top of
center rib on fuel pressure regulator, while rounded side
engages bottom of tabs on housing.

Route ground wire around index pin side of end cap and
install spade terminal into slot in fuel filter shell.

Install top plate. See

4-14 2011 Touring Service: Fuel System

4.9

FUEL LEVEL SENDER

REMOVAL

Remove top plate. See

Disconnect 2-place connector to release fuel level sender
from wire harness.

NOTE

Looking into fuel tank at bracketry at top of tunnel, note that
finger on front bracket points forward, while finger on rear
bracket points rearward. See

Figure 4-16

Reaching into fuel tank, pull up on front finger and slide
fuel level sender bracket rearward until four ears on
bracket are free of catches at top of tunnel.

Remove fuel level sender from left side of fuel tank. See

Figure 4-17

sm04400

1. Fuel level sender bracket (front finger)
2. Fuel level sender connector
3. Top plate connector

Figure 4-16. Front Finger (Fuel Level Sender Bracket)

sm04194

Figure 4-17. Fuel Level Sender

INSTALLATION

With the finger on the fuel level sender bracket pointing
forward, install fuel level sender into left side of fuel tank.

Engage four ears on fuel level sender bracket with front
set of catches at top of tunnel. Push fuel level sender
bracket forward until ears are fully engaged.

Connect 2-place connector to attach fuel level sender to
wire harness.

Install top plate. See

2.23 HANDLEBARS, Heated Handgrips

2011 Touring Service: Fuel System 4-15

4.10

TWIST GRIP SENSOR

REMOVAL

Remove main fuse.

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

Release the right switch housing and front brake control
from the handlebar. See

7.40 HANDLEBAR SWITCH

ASSEMBLIES

Models with heated handgrips:

Pry end cap from

handgrip and pull connector out through end of handgrip.
See

. It is not

necessary to disconnect the heated handgrip power or
interconnect connectors.

NOTE

To remove the handgrip, a slight tug may be necessary.

Remove the handgrip from the end of the handlebar.

If present, remove two harness retainers from holes in
handlebar.

NOTE

The twist grip sensor jumper harness connector [204] is a 6-
place Molex (black).

Road King models:

See

Figure 4-18

. Remove headlamp

and handlebar clamp shroud. See

2.44 HEADLAMP

NACELLE: ROAD KING MODELS

. Remove twist grip

sensor jumper harness connector from T-stud on fork stem
nut lock plate and disconnect.

Fork mounted fairing models:

See

Figure 4-19

. Remove

outer fairing. See

2.34 UPPER FAIRING AND WIND-

SHIELD: FORK MOUNTED FAIRING MODELS

. Remove

twist grip sensor jumper harness connector from T-stud
and disconnect.

Frame mounted fairing models:

See

Figure 4-20

Remove outer fairing and instrument bezel. See

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS

and

2.39 INSTRUMENT

BEZEL: FRAME MOUNTED FAIRING MODELS

. Discon-

nect twist grip sensor jumper harness connector.

NOTE

The twist grip sensor connector can break if the twist grip
sensor is pulled too hard. The connector is not serviceable.
Damage requires replacement of the twist grip sensor jumper
harness or twist grip sensor assembly.

sm04182

Figure 4-18. Twist Grip Sensor Jumper Harness Connector

(Road King models)

sm04184

Figure 4-19. Twist Grip Sensor Jumper Harness Connector

(fork mounted fairing models)

7.40 HANDLEBAR SWITCH ASSEMBLIES

4-16 2011 Touring Service: Fuel System

sm06653

Figure 4-20. Twist Grip Sensor Jumper Harness Connector

(frame mounted fairing models)

Carefully pull twist grip sensor out of handlebar while
feeding jumper harness into center of handlebar. Pull out
only as far as necessary to access the connectors.

NOTE

The latch on the pin housing is very fragile. Use extreme care
when releasing it. The connector is not serviceable and can
only be obtained as part of the twist grip sensor jumper har-
ness.

10. Gently insert a small flat blade screwdriver between pin

and socket housings as shown in

Figure 4-21

and separate

housings. Do not pivot or rotate screwdriver after insertion
or damage to pin housing may occur.

11. See

Figure 4-22

Models with heated handgrips:

Sep-

arate the interconnect harness connector (2).

12. Remove twist grip sensor.

sm04157

Figure 4-21. Gently Insert Screwdriver to Disconnect Twist

Grip Sensor Connector

sm06655

1. TGS connector
2. Interconnect harness connector

Figure 4-22. Heated Handgrip Connectors

INSTALLATION

NOTE

The seal cap protects the TGS terminals from dirt and moisture,
and also serves as a retention device for installation of the
throttle grip.

Verify that seal cap is installed at end of twist grip sensor.
If seal cap is not present, it may be engaged inside throttle
grip.

Check condition of O-ring on seal cap. O-ring is only
available as part of the seal cap assembly.

See

Figure 4-23

. Install seal cap engaging legs in

slots at end of twist grip sensor.

Connect TGS connector to TGS jumper harness.

Models with heated handgrips:

See

Figure 4-22

. Con-

nect the interconnect harness connector (2).

See

Figure 4-24

. Gently draw jumper harness into

handlebar while guiding TGS into end of handlebar. Align
index tabs on twist grip sensor into slots in handlebar.
Verify that the TGS is completely engaged into the slots
in the handlebar.

Position hand grip so any cosmetic features are properly
positioned. Install the handgrip and rotate to verify that
internal splines are engaged with the twist grip sensor.

Models with heated handgrips:

Install handgrip and

connect heated handgrip connector. See

2.23 HANDLE-

BARS, Heated Handgrips

. Install end cap.

Install switch housing and brake lever/master cylinder
assembly. See

2.44 HEADLAMP NACELLE: ROAD KING

2011 Touring Service: Fuel System 4-17

sm04169

Figure 4-23. Install Seal Cap (models without heated grips)

sm04172

Figure 4-24. Install Twist Grip Sensor

Connect twist grip sensor jumper harness connector and
secure on T-stud if equipped.

Road King models:

Install handlebar clamp shroud and

headlamp. See

MODELS

10.

Fork mounted fairing models:

Install outer fairing. See

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS

11.

Frame mounted fairing models:

Install outer fairing and

instrument bezel. See

2.38 UPPER FAIRING AND

WINDSHIELD: FRAME MOUNTED FAIRING MODELS

and

2.39 INSTRUMENT BEZEL: FRAME MOUNTED

FAIRING MODELS

, respectively.

12. If present, install two cable clips on handlebar switch

conduit into holes in handlebar.

13. Install main fuse.

NOTE

Whenever a new twist grip sensor (or ECM) is installed, place
the engine run/stop switch in the RUN position and turn the
ignition/light keyswitch to IGNITION and then back to OFF four
times (without starting engine). Allow at least three seconds
to elapse between ignition cycles. As the ECM uses the first
four ignition cycles to establish the optimum idle speed, there
may be initial performance problems if the procedure is not
performed.

TWIST GRIP SENSOR JUMPER HARNESS

Removal

Remove twist grip sensor.

See

Figure 4-25

. Securely attach chaser wire to jumper

harness.

Gently pull jumper harness out through slot at center of
handlebar. Remove chaser wire from jumper harness.

Installation

Securely attach chaser wire to jumper harness. If
equipped, secure heated handgrip connector to harness
with electrical tape.

Carefully draw connector and jumper harness through
handlebar while feeding harness into handlebar.

Remove chaser wire from jumper harness.

Install twist grip sensor.

sm04176

Figure 4-25. Attach Chaser Wire to Twist Grip Sensor

Jumper Harness