Harley Davidson 2011 Touring Models. Service Manual — page 37

7.7 SYSTEM FUSES AND RELAYS

2011 Touring Service: Fuel System 4-19

4.12

ENGINE TEMPERATURE SENSOR (ET)

REMOVAL

Remove main fuse. See

7.7 SYSTEM FUSES AND

RELAYS

Loosen horn bracket bolt to front cylinder head. Remove
horn bracket bolt (with flat washer) from rear cylinder head
and swing horn bracket forward.

Pull back boot at back of front cylinder and remove ET
sensor connector [90].

See

Figure 4-27

. Remove sensor.

sm04501

Figure 4-27. ET Sensor

INSTALLATION

Hand start

new

ET sensor into bore at back of front cyl-

inder.

Tighten to 120-180

in-lbs

(13.6-20.3 Nm).

Install ET sensor connector [90]. Pull boot over connector.

Install main fuse. See

4-20 2011 Touring Service: Fuel System

4.13

INDUCTION MODULE

REMOVAL

TOOL NAME

PART NUMBER

INTAKE MANIFOLD WRENCH

HD-47250

Remove fuel tank. See

Remove air cleaner and backplate. See

4.4 AIR CLEANER

ASSEMBLY

See

Figure 4-28

. If ACR equipped, remove ACR con-

nectors and retainer from mounting bracket (3).

Pull purge tube from fitting (2) at top of induction module
(California models only).

Remove TMAP sensor connector (5).

Remove front fuel injector connector (1) and rear fuel
injector connector (6).

Remove TCA connector (4). Cut anchored cable strap to
release connector conduit from front right side of induction
module.

Remove right side screws from front and rear cylinder
head flange adapters. For best results, use the INTAKE
MANIFOLD WRENCH (Part No. HD-47250). See

Figure 4-29

Loosen left side screws from flange adapters. Slots in
flanges make removal of screws unnecessary.

10. Slide induction module out right side of motorcycle.

11. Remove seals from flange adapters. Discard seals.

Remove flange adapters from outlet ports of induction
module.

sm04089

TMAP sensor [80]

Front fuel injector [84]

Purge tube fitting/cap

Rear fuel injector [85]

Fuel rail

Mounting bracket

TCA [211]

Fuel supply tube

Figure 4-28. Induction Module Assembly

2011 Touring Service: Fuel System 4-21

sm04384

Figure 4-29. Intake Manifold Wrench

INSTALLATION

TOOL NAME

PART NUMBER

INTAKE MANIFOLD WRENCH

HD-47250

With the counterbore facing outward, slide flange adapters
onto the induction module.

Place a

new

seal in each flange adapter with the beveled

side against the counterbore.

See

Figure 4-28

. Slide induction into position until slots

engage screws on left side.

Start right side screws. For best results, use the INTAKE
MANIFOLD WRENCH (Part No. HD-47250).

Loosely install two breather bolts to temporarily fasten
mounting bracket to cylinder heads.

Tighten right side flange adapter screws until snug. Tighten
left side screws to 96-144

in-lbs

(10.9-16.3 Nm).

Tighten right side screws to 96-144

in-lbs

(10.9-16.3 Nm).

See

Figure 4-28

. Install rear fuel injector connector (6)

and front fuel injector connector (1).

Install TMAP sensor connector (5).

10. Route TCA connector and conduit straight down between

induction module and front cylinder staying inboard of
mounting bracket. Install

new

anchored cable strap in hole

at front right side of induction module and loosely capture
TCA conduit.

11. Route conduit rearward under induction module and install

TCA connector (4). Tighten cable strap and cut any excess
cable strap material.

12. Connect purge tube to fitting (2) (California models only).

On non-California models, inspect rubber cap for tears,
cracks or signs of deterioration. Replace cap if damaged
or missing.

13. If equipped with ACR, install ACR connector retainer on

mounting bracket (3) and secure connectors to it.

14. Install fuel tank. See

15. Install backplate and air cleaner. See

4.4 AIR CLEANER

ASSEMBLY

4-22 2011 Touring Service: Fuel System

4.14

TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)

GENERAL

See the electrical diagnostic manual for information on the
function and testing of the temperature/manifold absolute
pressure (TMAP) sensor.

REMOVAL

Remove fuel tank. See

Remove hex screw to release TMAP sensor bracket from
induction module. Discard screw.

See

Figure 4-30

. While rotating TMAP sensor slightly, pull

straight up to release pressure port from hole in induction
module.

sm04080

Figure 4-30. TMAP Sensor

INSTALLATION

Inspect O-ring on pressure port for cuts, tears or signs of
deterioration. Install

new

O-ring if necessary.

With the electrical connector facing toward the rear of the
induction module, insert pressure port on TMAP sensor
into hole in induction module.

Align hole in TMAP sensor bracket with threaded hole in
induction module.

Install

new

hex screw and tighten to 84-108

in-lbs

(9.5-

12.2 Nm).

Install fuel tank. See

2011 Touring Service: Fuel System 4-23

4.15

OXYGEN SENSORS (O2)

GENERAL

See the electrical diagnostic manual for information on the
function and testing of the oxygen sensor (O2).

REMOVAL

TOOL NAME

PART NUMBER

OXYGEN SENSOR WRENCH

HD-50017

Remove main fuse. See

7.7 SYSTEM FUSES AND

RELAYS

See

Figure 4-31

. Cut cable straps (3, 4) and disconnect

oxygen sensor connector (1 or 2).

Release harness from retainer (5).

Using OXYGEN SENSOR WRENCH (Part No. HD-50017),
remove oxygen sensor (6).

sm06656

Cable strap to brake hose

Rear oxygen sensor connector

Front oxygen sensor connector

Cable retainer

Oxygen sensors

Cable strap to frame

Figure 4-31. Oxygen Sensors

7.7 SYSTEM FUSES AND RELAYS

4-24 2011 Touring Service: Fuel System

INSTALLATION

TOOL NAME

PART NUMBER

OXYGEN SENSOR WRENCH

HD-50017

NOTES

•

Do not install sensors that have been dropped or impacted
by other components. Damage to the sensing element
may have occurred.

•

Replacement sensors have anti-seize pre-applied to the
threads. Apply a thin coat of anti-seize lubricant to the
threads of sensors that are to be reused. Never use any
other lubricant or sealant.

If reusing oxygen sensor:

Remove used seal and install a

new

one.

Apply a light coating of SILVER GRADE ANTI-SEIZE
(Part no. 98960-97) to threads.

Using OXYGEN SENSOR WRENCH (Part No. HD-50017),
install oxygen sensor and tighten to 14 ft-lbs (19 Nm).

See

Figure 4-31

. Route harness along lower frame and

above the rear engine mount. Secure in harness retainer
(5).

NOTE

Verify connector halves are clean and free of grease or other
contaminants. NEVER apply dielectric grease, cleaning agents,
or any other lubricants, sealants or fluids to oxygen sensor
connectors. Any such application will result in signal trouble
and sensor failure.

Connect sensor connector (1 or 2). Secure sensor har-
nesses with

new

cable straps to rear frame down tube (3)

and brake hose (4).

Install main fuse. See

2011 Touring Service: Fuel System 4-25

4.16

FUEL INJECTORS

GENERAL

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)

See the electrical diagnostic manual for information on the
function and testing of the fuel injectors.

REMOVAL

Remove induction module. See

4.13 INDUCTION

MODULE

Remove T25 TORX screw to release fuel supply tube
clamp from fuel rail.

See

Figure 4-32

. Rotate fuel supply tube clamp 90 degrees

in a clockwise direction and then remove from groove in
fuel supply tube fitting.

Pull fuel supply tube from fuel rail bore and remove two
O-rings and two sealing washers. Discard O-rings and
sealing washers.

Pull fuel injectors with attached fuel rail from induction
module. To overcome the resistance of the bottom O-ring
on both fuel injectors, gently rock assembly back and forth
while pulling.

Pull fuel injectors from fuel rail. To overcome the resistance
of the top O-ring, gently rock each fuel injector while
pulling.

Remove O-rings from fuel injectors. Discard O-rings.

sm04095

Figure 4-32. Rotate Fuel Supply Tube Clamp

INSTALLATION

Apply a very light film of clean engine oil to

new

O-rings.

Install O-rings on fuel injectors.

Push open end of fuel injectors (opposite cone spray) into
fuel rail.

Rotate fuel injectors, so that the electrical connectors are
on the outboard side. Push cone spray end of fuel injectors
into bores of induction module until slot at bottom of fuel
rail engages machined tab at top of induction module.

Install

new

O-ring and sealing washer in fuel rail bore.

Install second O-ring and second sealing washer.

Push fuel supply tube into fuel rail bore.

Rotate fuel supply tube in a clockwise direction until
tapered end of quick connect fitting is pointing upward.
Now rotate tube an additional 90°, so that fitting is pointing
rearward (toward TCA on induction module).

Engage slot on fuel supply tube clamp in groove of fuel
supply tube fitting. Rotate fuel supply tube clamp 90° in a

4-26 2011 Touring Service: Fuel System

counter-clockwise direction until curled lip on fuel supply
tube clamp engages flange on fuel rail.

Align thru holes in fuel rail and fuel supply tube clamp with
threaded hole in induction module. Install T25 TORX screw
and tighten to 66-82

in-lbs

(7.5-9.3 Nm).

Install induction module.

4.13 INDUCTION MODULE

Fuel Pump and Fuel Level Sender Wire Harness

2011 Touring Service: Fuel System 4-27

4.17

FUEL PUMP

GENERAL

When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)

Carefully inspect tubes for cuts, tears, holes or other damage.
Replace fuel pump if any damage is found. Even a small hole
can cause a reduction in fuel pressure.

Refer to the electrical diagnostic manual for information on the
function and testing of the fuel pump.

REMOVAL

Remove top plate. See

4.6 FUEL TANK TOP PLATE

Remove fuel level sender. See

4.9 FUEL LEVEL SENDER

Pull up on transfer tube bracket to release two tabs at
bottom from slots at top of fuel pump bracket.

Depress collar on each side of fitting to disconnect transfer
tube from transfer tube bracket.

See

Figure 4-33

. Pull up on rear finger and slide fuel pump

bracket forward until four ears on bracket are free of
catches at top of tunnel.

See

Figure 4-34

. Remove fuel pump from left side of fuel

tank. For best results, rotate fuel pump assembly 90
degrees in a clockwise direction until transfer tube connec-
tion is pointing rearward, and then pull from fuel tank.

If necessary, further disassemble fuel pump assembly as
follows:

Reaching into fuel tank, release transfer tube from
weld clip on right side of tunnel and remove from fuel
tank.

Depress arms on fuel inlet strainer and remove from
slots in fuel pump housing.

Inspect the condition of the fuel pump wiring. If the
wiring needs to be replaced, see

4.17 FUEL PUMP,

sm04402

1. Fuel pump bracket (rear finger)
2. Transfer tube/bracket
3. Fuel pump to fuel filter fitting

Figure 4-33. Rear Finger (Fuel Pump Bracket)

sm04404

Figure 4-34. Fuel Pump Assembly

INSTALLATION

If removed, assemble fuel pump assembly as follows:

Reaching into fuel tank, capture transfer tube in weld
clip on right side of tunnel.

Install fuel inlet strainer at bottom of fuel pump enga-
ging arms in slots of fuel pump housing.

Install fuel pump into left side of fuel tank. For best results,
hold fuel pump assembly, so that transfer tube connection
is pointing rearward, and then insert into fuel tank. Now
rotate assembly 90 degrees in a counter-clockwise direc-
tion.

Look into fuel tank to verify that fuel inlet strainer lies flat
and that ends are not folded under fuel pump. Also verify

4-28 2011 Touring Service: Fuel System

that wire harness is still captured in molded clip at front of
fuel pump bracket.

With the finger on the fuel pump bracket pointing rearward,
engage four ears on bracket with rear set of catches at
top of tunnel. Push fuel pump bracket rearward until ears
are fully engaged.

Install transfer tube onto transfer tube bracket. Fit two tabs
at bottom of transfer tube bracket into slots at top of fuel
pump bracket. Verify that transfer tube is still captured in
weld clip on right side of tunnel and that free end is in
contact with bottom of fuel tank.

Install fuel level sender. See

4.9 FUEL LEVEL SENDER

Install top plate. See

4.6 FUEL TANK TOP PLATE

FUEL PUMP AND FUEL LEVEL SENDER
WIRE HARNESS

Removal

NOTE

Damaged wiring, terminals and/or connectors requires
replacement of the wire harness. Do not replace the special
teflon coated wiring with ordinary bulk wire. Ordinary insulation
materials may deteriorate when in contact with gasoline.

Remove fuel pump. See

4.17 FUEL PUMP

Cut cable strap to release wire harness and both fuel pump
and transfer tubes from arm of fuel pump bracket.

Release wire harness from molded clip at front of fuel
pump bracket.

Remove connector at top of fuel pump.

Installation

Install connector at top of fuel pump.

Route wire harness rearward and then forward under arm
of fuel pump bracket. Install

new

cable strap at elbow

capturing fuel pump and transfer tubes at top of arm and
wire harness at bottom. See

Figure 4-35

Route wire harness through molded clip at front of fuel
pump bracket. See

Figure 4-36

Install fuel pump. See

4.17 FUEL PUMP

sm04405

Figure 4-35. Cable Wires in Cable Strap

sm04406

Figure 4-36. Capture Wires in Molded Clip

2011 Touring Service: Fuel System 4-29

4.18

FUEL PRESSURE TEST

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

See

Figure 4-37

. The fuel pump fuse is located in the fuse

block under the left side cover. The fuel pump can be turned
on with DIGITAL TECHNICIAN II (Part No. HD-48650) or by
applying battery voltage to the fuel pump fuse.

Improper fuel system pressure may contribute to one of the
following conditions:

•

Cranks, but won't run.

•

Cuts out (may feel like ignition problem).

•

Hesitation, loss of power or poor fuel economy.

NOTE

Refer to the electrical diagnostic manual for further information
on the function and testing of the fuel system.

sm05910

1. Fuel pump fuse
2. Main fuse

Figure 4-37. Fuse Blocks

TESTING

TOOL NAME

PART NUMBER

FUEL PRESSURE GAUGE

HD-41182

FUEL PRESSURE GAUGE ADAPTER

HD-44061

NOTE

Avoid kinking the fuel supply line when installing/removing the
fuel pressure gauge and adapters.

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)

Purge and disconnect fuel supply line. See

4.5 FUEL

TANK, Removal

. Leave the fuel pump fuse removed.

NOTE

Use two fuel pressure gauge adapters to prevent twisting of
the fuel supply line. Tug on all connections to verify they are
secure.

Install fuel pressure gauge adapters as follows:

See

Figure 4-38

. Connect two FUEL PRESSURE

GAUGE ADAPTER (Part No. HD-44061) together.

Connect fuel line to adapter assembly.

Connect adapter assembly to quick-connect fitting on
fuel tank.

sm02625

Figure 4-38. Fuel Pressure Gauge Adapters

sm02626

1. Fuel supply line
2. Adapter to fuel line
3. Adapter to fuel tank
4. Pressure adapter Schroeder valve union
5. Fuel valve (closed position)

Figure 4-39. Fuel Line

4-30 2011 Touring Service: Fuel System

sm02627

Figure 4-40. Fuel Pressure Gauge Installed (Typical)

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)

Verify that the fuel valve and air bleed petcock on the
FUEL PRESSURE GAUGE (Part No. HD-41182) are
closed.

See

Figure 4-39

. Connect fuel pressure gauge to

Schroeder valve closest to the fuel tank.

Install fuel pump fuse.

Start and idle engine to pressurize the fuel system. Open
the fuel valve.

Position the clear air bleed tube in a suitable container
and purge the gauge and hose of air. Close the petcock.

Vary the engine speed and note the reading of the pres-
sure gauge. Fuel pressure should remain steady at 55-62
psi (380-425 kPa).

NOTE

If the fuel pressure is not within specification, see electrical
diagnostic manual for further diagnosis.

Gasoline can drain from the fuel line and adapter when
removed. 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. (00255a)

Turn the engine off. Purge the fuel pressure gauge of
gasoline and remove fuel pressure gauge from Schroeder
valve. Install protective cap.

10. Remove adaptor fitting assembly from fuel supply line and

quick-connect fitting on fuel tank.

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)

11. Connect fuel supply line fitting to fuel tank quick-connect.

Tug on fuel supply line fitting to verify that it is secure.

2011 Touring Service: Fuel System 4-31

4.19

EXHAUST SYSTEM

MUFFLERS

Removal

Remove saddlebags. See

See

Figure 4-41

. Remove two fasteners (2) and lock

washers.

Loosen clamp (23).

Pull and twist muffler to remove.

Inspect rubber mount (1) for deterioration or damage.
Replace as necessary.

Installation

Slide

new

muffler clamp onto muffler. Push muffler

squarely onto exhaust pipe.

Secure muffler to bracket (3) with fasteners (2) and lock-
washers. Tighten fasteners to 96-144

in-lbs

(10.8-16.3

Nm).

Position and tighten clamp (23) to 38-43 ft-lbs (51.5-58.3
Nm).

Install saddlebags. See

SYSTEM REMOVAL

Remove saddlebags. See

4.19 EXHAUST SYSTEM, Mufflers

Remove mufflers. See

Remove seat. See

2.25 SEAT

Remove right side front footboard and brackets from frame.
See

2.49 FOOTBOARDS AND FOOTRESTS, Rider

Footboards

On HDI models, disconnect cable to exhaust valve actuator
as follows:

Locate active exhaust valve just forward of the right
side muffler. Push cam rearward to remove tension
from cable, and then release ball end from slot.

Remove cable clip from slotted flange at front of active
exhaust valve.

Disconnect front and rear O2 sensor connectors.

See

Figure 4-41

. Remove heat shields (10, 19, 22) from

pipes.

NOTE

Some models are equipped with only a single muffler on the
right side.

Loosen clamp (4).

Remove fastener (6) and bracket (7).

10. Pull and twist on crossover pipe to remove (8).

11. Remove two flange nuts (17) to release front header pipe

from studs of front cylinder head. Slide exhaust flange
down header pipe to improve clearance around exhaust
port.

12. Remove two flange nuts (17) to release rear header pipe

from studs of rear cylinder head.

13. Remove flange nut (21) and carriage bolt (16).

14. Remove exhaust from motorcycle.

15. Remove and discard gaskets (13) from front and rear

exhaust ports.

16. Inspect retaining rings (15) and flanges (14). Replace as

necessary.

4-32 2011 Touring Service: Fuel System

sm05921

13.

Gasket (2)

Rubber mount

14.

Fastener (4)

Exhaust flange (2)

15.

Retaining ring (2)

Bracket (2)

16.

Clamp

Carriage bolt

17.

Flange nut (4)

Gasket

18.

Flange bolt

Exhaust bracket

19.

Heat shields, header pipe, front

Exhaust support clamp

20.

Crossover pipe

Worm clamps

21.

Flange locknut

Fastener (2)

10.

22.

Heat shield, crossover pipe

Heat shield, header pipe, rear

23.

11.

Muffler clamp

O2 Sensor (2)

12.

24.

Transmission exhaust bracket

Muffler

Figure 4-41. Exhaust System

SYSTEM INSTALLATION

See

Figure 4-41

. If removed, install transmission exhaust

bracket (12) and tighten fasteners (9) to 84-132

in-lbs

(9.5-14.9 Nm).

Install

new

gaskets in both the front and rear cylinder head

exhaust ports with the tapered side out.

Place exhaust header pipe into position on motorcycle
and start two exhaust flange nuts to secure front header
pipe to studs of front cylinder head.

Roll pipe into position at rear cylinder, making sure welded
bracket on header pipe is below the side exhaust bracket
(18).

4.19 EXHAUST SYSTEM, Mufflers

2011 Touring Service: Fuel System 4-33

Start two exhaust flange nuts to secure rear header pipe
to studs of rear cylinder head.

Secure header pipe to side exhaust bracket (18) with
carriage bolt (16) and flange nut (21). Do not tighten at
this time.

NOTE

Some models are equipped with only a single muffler on the
right side.

Slide

new

clamp (4) onto crossover pipe.

Install

new

gasket (5). Twist and push crossover pipe (8)

onto exhaust header pipe.

Install exhaust support clamp (7) and secure with fastener
(6). Do not tighten.

10. Install mufflers. See

NOTES

•

Verify that the exhaust components do not contact the
motorcycle frame or any mounted components.

•

Verify that no components are in a bind before and during
tightening to reduce the chance of unwanted noise or
vibration.

11. Tighten the exhaust system as follows:

Tighten the bottom nut of the rear cylinder head
exhaust flange to 9-18

in-lbs

(1-2 Nm). Tighten the

top nut to 100-120

in-lbs

(11.3-13.6 Nm). Final tighten

the bottom nut to 100-120

in-lbs

(11.3-13.6 Nm).

Tighten the top nut of the front cylinder head exhaust
flange to 9-18

in-lbs

(1-2 Nm). Tighten the bottom

nut to 100-120

in-lbs

(11.3-13.6 Nm). Final tighten

the top nut to 100-120

in-lbs

(11.3-13.6 Nm).

Tighten flange locknut (21) to 20-25 ft-lbs (27.1-33.9
Nm).

Tighten crossover pipe clamp (4) to 25-30 ft-lbs (33.9-
40.7 Nm).

Tighten fastener (6) to 14-18 ft-lbs (19.0-24.4 Nm).

NOTES

•

Verify that the heat shields do not contact the motorcycle
frame or any mounted components.

•

See

Figure 4-42

. Install crossover pipe heat shield with

the longer straight portion toward the muffler.

12. Install heat shields. Position each worm drive clamp so

that screw is on the outboard side in the most accessible
position and tighten to 20-40

in-lbs

(2.3-4.5 Nm).

13. Connect O2 sensor connectors and install

new

cable strap

to secure leads to rear frame. Secure in harness retainer
on lower frame.

14. On HDI models, connect cable to exhaust valve actuator

as follows:

Install cable clip onto slotted flange at front of active
exhaust valve.

Push cam rearward and install ball end of cable into
slot. Verify that cable is properly seated in channel of
active exhaust valve.

15. Install right side front footboard and brackets. See

2.49 FOOTBOARDS AND FOOTRESTS, Rider Foot-
boards

16. Install seat. See

2.25 SEAT

17. Install saddlebags. See

sm06146

Figure 4-42. Crossover Pipe Heat Shield