Harley Davidson 2009 Dyna Models. Service manual — page 21
sm02605
Figure 4-16. Engine Temperature Sensor Removal
INSTALLATION
1.
Hand start new ET sensor into cylinder head bore 2-3
turns.
2.
Tighten sensor to 10-15 ft-lbs (13.6-20.3 Nm).
3.
Connect ET sensor connector [90].
4.
Pull boot over connector.
5.
See
. Install fuel line fitting.
6.
See
. Install fuel pump fuse.
7.
Connect negative battery cable.
2009 Dyna Service: Fuel System 4-15
4.10
INDUCTION MODULE
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)
1.
Gain access to the induction module by removing fuel tank
hardware and fuel line. Carefully pivot tank upward and
prop in position. See
2.
Remove air cleaner backplate. See
.
3.
See
. Pull purge hose from fitting (5) at top of
induction module (California models only).
4.
See
. Pull idle cable barrel (1) from upper hole
in throttle wheel. Pull throttle cable barrel (2) from lower
hole. Using slots, release idle and throttle cables from
guides in throttle cable bracket.
5.
. Remove idle air control connector (3)
[87] and manifold absolute pressure sensor connector (7)
[80].
6.
Remove front fuel injector connector (1) [84] and rear fuel
injector connector (8) [85].
7.
Remove throttle position sensor connector (4) [88] and
intake air temperature sensor connector (6) [89].
2
3
4
5
6
7
8
9
10
11
1
sm02356
7.
1.
MAP sensor [80]
Front fuel injector [84]
2.
8.
Throttle cable bracket
Rear fuel injector [85]
9.
3.
Rear mounting flange
IAC connector [87]
4.
10.
TP sensor [88]
Fuel supply tube
11.
5.
Front mounting flange
Purge hose fitting (used on California models only)
6.
IAT sensor [89]
Figure 4-17. Induction Module
8.
On left side of vehicle, loosen two hex screws holding front
and rear mounting flanges (9, 11) to cylinder head.
9.
On right side of vehicle, remove two Allen screws holding
front and rear mounting flanges to cylinder head. Remove
induction module from vehicle.
Gasoline can drain from the fuel line when disconnected
from induction module. Gasoline is extremely flammable
and highly explosive, which could result in death or ser-
ious injury. Wipe up spilled fuel immediately and dispose
of rags in a suitable manner. (00269a)
4-16 2009 Dyna Service: Fuel System
10. See
. If fuel supply line (2) is being replaced,
squeeze ends of tab (1) and pull tab away from fuel supply
line to release from fuel supply tube (3).
11. Remove seals from flange adapters. Discard seals.
Remove flange adapters from outlet ports of induction
module.
4
3
2
1
sm02357
1.
Idle cable barrel
2.
Throttle cable barrel
3.
Throttle wheel
4.
Throttle cable bracket
Figure 4-18. Throttle/Idle Cables
INSTALLATION
1.
See
. Place a new seal in each mounting
flange (9, 11) with the beveled side in against the counter-
bore.
NOTE
When induction module is positioned on manifold mounting
screws, be sure the flanges are installed correctly on the
manifold. Be sure the rubber seals are in place.
2.
Place intake manifold seal, flanges, and induction module
in position. Install the manifold mounting screws finger
tight.
3.
See
. Slide fuel supply line (2) onto fuel supply
tube (3). Push in on tab until it locks the fuel supply line
(2) on fuel supply tube (3). Tug on fuel supply line (2) to
verify it is locked into place.
4.
. Install sleeve on throttle cable housing
into cable guide at top of throttle cable bracket (4). Drawing
throttle cable downward, fit barrel end (2) into lower hole
in throttle wheel (3). Install sleeve and spring on idle cable
housing into cable guide at bottom of throttle cable bracket
inserting barrel end (1) into upper hole in throttle wheel.
5.
See
. On California models, attach purge hose
to fitting (5) on throttle body.
6.
Connect front (1) and rear (8) fuel injector connectors, IAC
(3) connector, MAP sensor (7) connector, TP sensor (4)
connector and IAT (6) sensor connector.
7.
Install air cleaner back plate. See
8.
Tighten manifold mounting screws to 96-144 in-lbs (10.8-
16.3 Nm).
9.
Turn the Ignition/Light Key Switch to ON and then back
to OFF to reset idle air control to park position.
10. Install air cleaner filter and cover.
11. Secure fuel tank. See
.
sm02358
Figure 4-19. EVAP Hose Connection
3
1
2
sm02756
1.
Tab
2.
Fuel supply line
3.
Fuel supply tube
Figure 4-20. Fuel Supply Line
2009 Dyna Service: Fuel System 4-17
4.11
IDLE AIR CONTROL (IAC)
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)
Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the idle air control
(IAC).
REMOVAL
1.
Remove induction module. See
.
2.
See
. Remove two fasteners (2) to release
throttle cable bracket (1) from induction module. Discard
fasteners.
3.
. Pull IAC (1) and O-ring (2) from throttle
body.
3
1
2
sm02607
1.
Throttle cable bracket
2.
Fasteners
3.
Idle air control (IAC)
Figure 4-21. Idle Air Control Location
2
1
sm02359
1.
Idle air control (IAC)
2.
O-ring
Figure 4-22. Idle Air Control
INSTALLATION
1.
. Apply clean engine oil to IAC O-ring (2).
Install O-ring in counterbore of induction module.
2.
With the electrical connector facing the rear left side of
the induction module, install idle air control into bore.
3.
Place idle air control and o-ring into throttle body. Be sure
o-ring is properly seated in throttle body groove.
4.
See
. Insert index pin (2) at bottom of throttle
cable bracket (1) into hole in boss at top of induction
module.
5.
. Install new throttle cable bracket
fasteners (2). Tighten to 20-35 in-lbs (2.3-4.0 Nm).
6.
Install induction module. See
1
2
sm02190
1.
Throttle cable bracket
2.
Index pin
Figure 4-23. Throttle Cable Bracket
4-18 2009 Dyna Service: Fuel System
4.12
MANIFOLD ABSOLUTE PRESSURE SENSOR
(MAP)
GENERAL
Refer to the electrical diagnostic manual for information on the
function and testing of the temperature/manifold absolute
pressure (TMAP) sensor.
REMOVAL
1.
Remove induction module. See
.
2.
See
. Remove two fasteners (2) to release
throttle cable bracket (1) from induction module. Discard
fasteners.
3.
Using appropriate tool, gently push up on MAP sensor
and attached seal to remove from intake manifold.
3
1
2
sm02608
1.
Throttle cable bracket
2.
Fasteners
3.
Manifold Absolute Pressure Sensor (MAP)
Figure 4-24. Throttle Cable Bracket Location
INSTALLATION
NOTE
. If the original sensor is re-installed, the seal
(1) must be inspected. Seals not in good condition could cause
vacuum leaks. Install new seal if necessary.
1.
Push MAP sensor and seal into intake manifold.
2.
With the electrical connector facing toward the rear of the
induction module (side opposite throttle wheel), insert MAP
sensor into hole in induction module.
3.
See
. Insert index pin (2) at bottom of throttle
cable bracket into hole in boss at top of induction module.
4.
. Install new throttle cable bracket
fasteners (2). Tighten to 20-35 in-lbs (2.3-4.0 Nm).
5.
Install induction module. See
2
1
sm02360
1.
Seal
2.
MAP sensor
Figure 4-25. MAP Sensor
1
2
sm02190
1.
Throttle cable bracket
2.
Index pin
Figure 4-26. Throttle Cable Bracket
2009 Dyna Service: Fuel System 4-19
4.13
OXYGEN SENSOR
GENERAL
Refer to the electrical diagnostic manual for information on the
function and testing of the oxygen sensor (O2).
REMOVAL
1.
. The (O2) sensors are installed in
threaded bosses on the inboard side of front and rear
exhaust pipes.
NOTE
. Front oxygen sensor connector is located in
front electrical caddy. For more information on the disassembly
and assembly of front electrical caddy see
.
2.
Open front electrical caddy and disconnect O2 sensor
connector (1). Remove any cable straps securing harness
before loosening and removing front O2 sensor.
3.
. Remove seat. Disconnect sensor con-
nector and remove any cable straps securing harness
before loosening and removing rear O2 sensor.
sm02361
Figure 4-27. Oxygen Sensors (Inboard Side of Exhaust
Pipes)
2
1
sm03722
1.
O2 sensor connector
2.
CKP sensor connector
Figure 4-28. Front Electrical Caddy and Connectors
sm02191
Figure 4-29. Rear O2 Connector and Harness
INSTALLATION
NOTES
•
Do not install sensors that have been dropped or impacted
by other components. Damage to the sensing element
may have occurred. Replacement sensor assemblies have
threads coated with anti-seize lubricant and new seal
rings.
•
If reinstalling the O2 sensor, apply a thin coat of ANTI-
SEIZE LUBRICANT (Part No. 98960-97) to threads of
each oxygen sensor prior to installing in header. Do not
use any other grease or sealant product on sensor threads.
The electrical connector must also be clean and free of
any dielectric grease.
1.
If sensor is being reinstalled, replace seal ring and coat
threads on sensor with LOCTITE ANTI-SEIZE.
2.
Thread sensor into threaded boss on exhaust pipe and
tighten to 29-44 ft-lbs (39.3-59.7 Nm).
NOTE
Ensure both connector halves are clean and free of any
dielectric grease. Never use dielectric grease on sealed con-
nectors.
3.
Route sensor harness to mating connector and connect.
Install cable straps that were removed during removal.
4.
Repeat above for other sensor.
4-20 2009 Dyna Service: Fuel System
4.14
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)
Refer to the electrical diagnostic manual for information on the
function and testing of the fuel injectors.
REMOVAL
1.
Remove induction module. See
.
NOTE
If not replacing fuel supply tube or o-rings, do not remove.
2.
. Remove fastener (1) retaining fuel supply
tube (2).
3.
Pull fuel supply tube from fuel rail. Remove sealing washer
(4) and o-ring (3) from fuel supply tube. Remove second
o-ring from fuel rail bore. Discard sealing washer and o-
rings.
4.
. 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.
5.
See
. Remove spring clips (2) from fuel
injectors. Pull fuel injectors from fuel rail. To overcome the
resistance of the top O-ring, gently rock each fuel injector
while pulling.
6.
Remove o-rings (1) from fuel injectors. Discard O-rings.
4
3
2
1
3
sm02362
1.
Fastener
2.
Fuel supply tube
3.
O-ring (2)
4.
Sealing washer
Figure 4-30. Fuel Supply Tube
2
5
3
4
1
sm02609
1.
Fork
2.
Lip
3.
Opening
4.
Rail tab
5.
Injector tab
Figure 4-31. Fuel Rail
INSTALLATION
1.
. Apply a thin coat of clean engine oil to
new fuel injector o-rings (1). Install on fuel injectors.
2.
. Push electrical connector side of fuel
injectors into fuel rail.
3.
With the concave side toward the fuel rail, install spring
clip into slot on fuel injector. In the installed position,
openings (3) in sides of clip engage lip (2) on fuel rail,
while fork (1) at back of clip captures rail tab (4) on fuel
injector.
4.
Rotate fuel injectors, so that the electrical connectors are
on the outboard side. Push fuel injectors into induction
module bores until tab on fuel rail engages machined slot
at top of induction module.
5.
See
. Slide new o-ring (3) down shorter neck
of the fuel supply tube until it contacts the collar. Slide
new sealing washer (4) down tube until it contacts O-ring.
Install second o-ring (3) in fuel rail bore.
6.
Push fuel supply tube (2) into fuel rail bore until clamp is
seated on round step of fuel rail. Install fastener (1) and
tighten to 90-110 in-lbs (10.2-12.4 Nm).
7.
Install induction module.
2009 Dyna Service: Fuel System 4-21
2
1
sm02363
1.
O-rings
2.
Spring clip
Figure 4-32. Fuel Injector
4-22 2009 Dyna Service: Fuel System
4.15
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 hose for cuts, tears, holes or other damage.
Replace hose 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
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)
1.
Purge the fuel supply line of high pressure gasoline.
a.
See
. Remove the fuel pump fuse from
fuse block.
b.
Start the engine and allow the vehicle to run.
c.
When the engine stalls, operate the starter for 3
seconds to remove any remaining fuel from the fuel
lines.
sm02188
Figure 4-33. Fuel Pump Fuse
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2.
Disconnect negative battery cable.
3.
Remove instrument console.
a.
For FXDC/FXDF models, see
b.
For FXDL, FXDB models, see
.
c.
For FXD models, see
4.
Disconnect console wiring.
Gasoline can drain from the crossover line when discon-
nected from fuel tank. Gasoline is extremely flammable
and highly explosive, which could result in death or ser-
ious injury. Wipe up spilled fuel immediately and dispose
of rags in a suitable manner. (00259a)
5.
Drain fuel tank.
a.
Obtain a short section of hose (5/16 inch I.D.). Insert
bolt in one end of hose and install hose clamp to verify
that end is securely plugged.
b.
See
. Cut clamp (1) from one end of
crossover hose (2). 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.
6.
See
. Unplug fuel pump and sender connector
(1) [141].
7.
Remove vent hose (3).
8.
Remove top plate screws (2) and discard.
9.
See
. On FXDL, FXDB, FXDF and FXDC
models, rotate top plate (3) until vent tube (1) clears fuel
tank.
2
1
sm02610
1.
Clamp
2.
Crossover hose
Figure 4-34. Fuel Crossover Hose
2009 Dyna Service: Fuel System 4-23
1
3
2
sm02192
1.
Fuel pump and sender connector [141]
2.
Screws (12)
3.
Vent hose
Figure 4-35. Top Plate Screws (Typical)
1
2
3
sm02193
1.
Vent tube
2.
Gasket
3.
Top plate
Figure 4-36. Fuel Line Clamp
10. See
. Depress tab and remove fuel
pump/sender wiring from top plate. Remove top plate.
11. See
. Depress tabs (1) and remove fuel line
(4) from fuel pump assembly (2).
12. Remove fuel gauge wiring harness (5) from clip (6).
13. Disconnect fuel pump connector (3).
14. See
. Lift fuel pump assembly tab. Push
assembly towards front of vehicle to disengage from fuel
tank.
15. Rotate fuel pump assembly clockwise and upward to
remove fuel pump assembly from fuel tank.
sm02194
Figure 4-37. Connector Tab
5
2
3
4
6
1
sm02612
1.
Tabs (2)
2.
Fuel pump assembly
3.
Fuel pump connector
4.
Fuel line
5.
Fuel gauge wiring harness
6.
Clip
Figure 4-38. Fuel Pump
sm02613
Figure 4-39. Fuel Pump Removal
4-24 2009 Dyna Service: Fuel System
17
16
15
14
12
11
10
9
8
7
6
5
4
13
3
1
2
sm02364a
10.
1.
Regulator clip
Sender
2.
11.
Top plate connector
Filter housing
12.
3.
O-ring
Fuel pump/sender wiring
4.
13.
Clip
Upper isolator
14.
5.
Fuel pump
End cap
6.
15.
Upper retainer
Lower isolator
16.
7.
Lower retainer
Filter
8.
17.
Regulator
Inlet sock
9.
O-ring
Figure 4-40. Fuel Pump/Fuel Gauge Sending Unit
DISASSEMBLY/ASSEMBLY
Fuel Filter
1.
. Depress tab and remove filter retainer
clip (1).
2.
Separate fuel pump body from end cap (2).
3.
. Remove O-ring (2).
4.
Remove fuel filter (1).
5.
Install new fuel filter.
6.
Install new o-ring.
7.
See
. Place end cap (2) on fuel pump body.
8.
Install fuel filter retainer clip (1).
Regulator
1.
See
. Remove wire terminal (3).
2.
Disengage clip (2) from regulator.
3.
Remove regulator from pump assembly.
4.
Install new O-ring on new regulator.
5.
Install regulator into pump assembly.
6.
Install clip over regulator.
2009 Dyna Service: Fuel System 4-25
7.
Replace wire terminal.
1
2
sm02614
1.
Fuel filter retainer clip
2.
End cap
Figure 4-41. Filter Retainer Clip
1
2
sm02615
1.
Fuel pump filter
2.
O-ring
Figure 4-42. Bail Bracket
1
2
3
sm02616
1.
Regulator
2.
Clip
3.
Wire terminal
Figure 4-43. Regulator
Inlet Sock
1.
. Depress tabs (2) securing inlet sock (1)
to upper retainer (3).
2.
Remove inlet sock from upper retainer.
NOTE
. In next step, be sure inlet sock engages fuel
pump inlet.
3.
See
. Install inlet sock (1) on upper retainer
(3). Be sure tabs (2) engage slots in body.
1
2
3
2
sm02617
1.
Inlet sock
2.
Tab (2)
3.
Upper retainer
Figure 4-44. Fuel Sock
4-26 2009 Dyna Service: Fuel System
2
1
sm02618
1.
Fuel pump inlet
2.
Inlet sock
Figure 4-45. Fuel Sock Installation
Fuel Pump
1.
See
. Using screwdriver, break tabs securing
fuel pump hose to end cap.
2.
Remove inlet sock. See
3.
. Disconnect fuel pump connector (1).
4.
. Depress tabs (1) and remove lower
retainer (2) from upper retainer.
5.
Remove fuel pump from fuel pump body.
6.
. Install lower isolator in lower retainer.
7.
Install upper isolator into upper retainer.
8.
Install fuel pump into upper retainer.
9.
. Install lower retainer.
10. See
. Install fuel pump hose into new end cap.
11. See
. Install fuel pump connector (1). Inspect
fuel pump wiring, (2) replace if damaged.
12. Install inlet sock. See
.
sm02619
Figure 4-46. Fuel Pump Hose Retaining Clip (2)
2
1
3
sm02620
1.
Fuel pump connector
2.
Wire harness
3.
Wire clip
Figure 4-47. Fuel Pump Connector
1
2
1
sm02621
1.
Tab (3)
2.
Fuel pump lower retainer
Figure 4-48. Filter Retainer Clip
INSTALLATION
NOTE
Fuel pump sits in left side of fuel tank.
1.
See
. Install fuel pump into left side of fuel tank
as shown.
2.
Rotate pump counterclockwise and downward into posi-
tion.
3.
See
. Install fuel pump so end cap (8) engages
mounting tabs (4).
4.
Connect fuel pump connector (7).
5.
Place fuel gauge wiring harness (5) into clip (6).
6.
Install new O-ring on fuel line (1). Install fuel line.
7.
Install new top plate gasket on fuel tank. Do not apply any
type of sealant to gasket.
2009 Dyna Service: Fuel System 4-27
sm02622
Figure 4-49. Fuel Pump Installation
4
5
2
8
7
1
3
6
sm02623
1.
Fuel line
2.
Tabs (2)
3.
Fuel pump assembly
4.
Mounting tabs (4)
5.
Fuel gauge wiring harness
6.
Clip
7.
Fuel pump connector
8.
End cap
Figure 4-50. Fuel Pump
8.
. Install fuel pump/sender wire connector
(4) on top plate (3).
9.
Install top plate.
a.
On FXDL and FXDF models, hold top plate at 90°
angle.
b.
. On all models, install sender wiring
into clip (3).
c.
. On FXDL, FXDB, FXDC and FXDF
models, making sure that vent tube is installed inside
of tank, rotate top plate into position.
10. Loosely install new sealing screws in top plate.
11. On FXDC and FXDF models, see
. Tighten
sealing fasteners using pattern shown to 20 in-lbs (2.3
Nm).
12. On FXD/FXDB/FXDL models, see
. Tighten
sealing fasteners using pattern shown to 20 in-lbs (2.3
Nm).
13. See
. Connect fuel pump/sending unit con-
nector [141].
14. Install instrument console.
a.
For FXDC/FXDF models, see
b.
For FXDL/FXDB models, see
.
c.
For FXD models, see
NOTE
In next step, be sure crimped end of clamp faces toward front
of vehicle.
15. Connect crossover hose with new clamps.
16. Connect the fuel pump fuse to the main wiring harness.
17. Connect negative battery cable.
18. Fill tank with gasoline and check for leaks.
19. Check fuel system pressure. See
.
3
1
2
4
sm02624
1.
Vent tube
2.
Gasket
3.
Top plate
4.
Fuel pump/sender wire connector
Figure 4-51. Top Plate
4-28 2009 Dyna Service: Fuel System
1
3
2
sm02195a
1.
Fuel gauge sender
2.
Removal tab
3.
Connector
Figure 4-52. Fuel Gauge Sender
1
3
2
sm02192
1.
Fuel pump and sender connector [141]
2.
Screws (12)
3.
Vent hose
Figure 4-53. Top Plate: FXDF
9
6
8
11
7
5
12
10
1
3
2
4
sm02196
Figure 4-54. Top Plate Torque Sequence (Typical)
2009 Dyna Service: Fuel System 4-29
12
11
8
4
2
6
10
9
5
1
3
7
sm02365
Figure 4-55. Top Plate Torque Sequence: FXD/FXDB/FXDL
4-30 2009 Dyna Service: Fuel System
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