Harley Davidson Sportster Models 2009. Service Repair Manual — page 32

Inspect the fuel tank for leaks or other damage. If a dam-
aged fuel tank cannot be successfully repaired, replace
it.

ASSEMBLE FUEL TANK

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)

See

Figure 4-24

. Install O-ring (5) on top ring (4). Ensure

it is seated properly.

Install top ring and clamp ring with screws (7).

See

Figure 4-25

. Tighten screws in the sequence shown

to 40-45 in-lbs (4.5-5.1 Nm).

See

Figure 4-24

. Install filler cap (1) with O-ring (2).

sm05461

Figure 4-25. Filler Housing Torque Sequence

INSTALLING FUEL TANK

NOTE

Be sure that wiring harnesses do not get pinched between fuel
tank and frame during tank installation.

Install fuel pump into fuel tank using new gasket. See

4.18 FUEL PUMP

See

Figure 4-26

. Install rubber grommets (3) in both front

mounting holes of fuel tank. Insert metal bushings (4) into
rubber grommets, oriented as shown. Make certain clip
nut (5) is installed on frame bracket.

Position fuel tank on motorcycle. Make certain that ignition
coil bracket is positioned between tank mount and frame
and that airbox mounting brackets are correctly mated.

Insert screw (6) with washer (2) through fuel tank front
mounting brackets and vehicle frame. Install remaining

washer and lock nut (7) on other end of screw. Do not
tighten at this time.

Secure pump harness to main harness retainer located
under fuel tank.

Make certain metal bushing (4) is located inside rear lower
rubber grommet (3) of fuel tank. Install screw (1), washer
(2), and upper grommet (3) and thread into clip nut (5).
Tighten to 15-20 ft-lbs (20.3-27.1 Nm).

Tighten front screw (6) and nut (7) to 15-20 ft-lbs (20.3-
27.1 Nm).

NOTE

Be sure airbox grommet is securely installed on induction
module and airbox opening. See

4.5 AIRBOX: XR MODELS

An improperly seated grommet could lead to accelerated engine
wear.

Secure airbox to brackets on bottom of fuel tank.

See

Figure 4-20

. Secure throttle cables to bottom of fuel

tank using a new loop retainer.

10. See

Figure 4-22

. Connect vent hose (3) and ground wire

(5) as shown. Route ground wire and vent hose in trough
in top of tank.

11. See

Figure 4-21

. Install fuel tank cover and secure with

four screws (1). Tighten screws to 24-30 in-lbs (2.7-3.4
Nm).

12. Connect fuel pump connector [141].

13. Connect fuel supply fitting. See

4.7 FUEL TANK: XR

MODELS, Reconnecting Fuel Hose and Filling Fuel Tank

sm05411

Rear screw

Washer (3)

Rubber grommet (6)

Metal bushing

Clip nut

Front screw

Locknut

Cap

Figure 4-26. Fuel Tank Mounting

HOME

2009 Sportster Service: Fuel System 4-19

RECONNECTING FUEL HOSE AND FILLING
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)

See

Figure 4-20

. Push up on release sleeve (1) and push

fuel hose fitting (2) into fuel pump module fuel pump quick-
connect fitting. Pull down on release sleeve to lock quick-
connect fitting. Tug on fuel hose fitting to make sure it is
securely locked in place.

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Fill fuel tank and carefully inspect for leaks around fuel
pump module.

Install main fuse. See

6.38 MAIN FUSE

Turn ignition switch ON and verify fuel pump is activated.
Carefully inspect for leaks at quick-connect fitting and
induction module. Turn ignition switch OFF.

Install left side cover.

HOME

4-20 2009 Sportster Service: Fuel System

4.8

THROTTLE POSITION (TP) SENSOR

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

Figure 4-27

. The Throttle Position (TP) sensor is located

on the side of the induction module and monitors the physical
position of the throttle shaft.

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the TP sensor.

sm01616

Induction module (XL models)

Induction module (XR models)

Throttle position (TP) sensor

Figure 4-27. Throttle Position (TP) Sensor Location

(Induction Module Removed From Vehicle for Clarity)

HOME

2009 Sportster Service: Fuel System 4-21

REMOVAL: XL MODELS

NOTE

It is not necessary to remove the induction module from XL
model vehicles in order to replace the TP sensor.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Remove air cleaner cover, air filter element and backing
plate assembly. See

4.4 AIR CLEANER: XL MODELS

NOTE

It is important to prevent contaminants from entering the TPS
connectors. Cover both the harness connector and the TPS
connector cavity with tape immediately after disconnecting
harness.

See

Figure 4-28

. Unplug TP sensor harness connector

[88B] from connector socket [88A] (4). Cover both con-
nectors with tape.

Remove two screws (5) and detach TP sensor (3) from
induction module (1).

sm01617

Induction module

Intake manifold

Throttle position (TP) sensor

TP connector socket [88A]

Screw (2)

Figure 4-28. Throttle Position (TP) Sensor Removal (XL

Models)

INSTALLATION: XL MODELS

NOTES

•

Throttle must be closed for proper installation of throttle
position sensor.

•

See

Figure 4-28

. Note orientation of TP sensor (3) relative

to induction module (1) body; connector socket is at

approximately the 7 o'clock position, facing toward intake
manifold (2).

See

Figure 4-29

. Fit pocket (3) of TP sensor (2) over

throttle shaft (4). Orient TP sensor correctly and line up
mounting holes in sensor with holes in body of induction
module (1).

Make sure TP sensor body is flush against mounting boss
on induction module body. Install two screws (5) to fasten
sensor to induction module. Tighten screws to 35 in-lbs
(4.0 Nm).

Open and close throttle plates and check for proper oper-
ation. Be sure mechanism operates smoothly without
binding or sticking.

Connect TP sensor harness socket connector [88B] to
sensor pin connector [88A].

Install air cleaner backing plate assembly, air filter element
and air cleaner cover. See

4.4 AIR CLEANER: XL

MODELS

Install main fuse and close left side cover. See

6.38 MAIN

FUSE

Start vehicle and check for proper throttle operation and
correct idle speed.

sm01618

Induction module

Throttle position (TP) sensor

Pocket

Throttle shaft

Screw (2)

Figure 4-29. Throttle Position (TP) Sensor Installation (XL

Models)

HOME

4-22 2009 Sportster Service: Fuel System

REMOVAL: XR MODELS

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)

Gasoline can drain from quick-connect fitting when
removing fuel line. 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. (00267a)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.7 FUEL TANK: XR MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Remove fuel tank and airbox. See

4.7 FUEL TANK: XR

MODELS

and

4.5 AIRBOX: XR MODELS

NOTE

It is important to prevent contaminants from entering the TPS
connectors. Cover both the harness connector and the TPS
connector cavity with tape immediately after disconnecting
harness.

See

Figure 4-30

. Unplug TP sensor harness connector

[88B] from connector socket [88A] (3). Cover both con-
nectors with tape.

Remove induction module from vehicle. See

4.11 INDUCTION MODULE: XR MODELS

Remove two screws (4) and detach TP sensor (2) from
induction module (1).

sm04957

Induction module

Throttle position (TP) sensor

TP sensor connector socket [88A]

Screw (2)

Figure 4-30. Throttle Position (TP) Sensor Removal (XR

Models)

INSTALLATION: XR MODELS

NOTES

•

Throttle must be closed for proper installation of throttle
position sensor.

•

See

Figure 4-30

. Note installed orientation of TP sensor

(2) relative to induction module (1) body; connector socket
is at approximately the 5:00 o'clock position.

See

Figure 4-31

. Place sensor over throttle shaft with the

connector housing (1) facing toward the mounting flange
(2) as shown.

Rotate the TP sensor counterclockwise into position as
shown in

Figure 4-30

Make sure TP sensor body is flush against mounting boss
on induction module body. Install two screws (4). Tighten
to 29 in-lbs (3.3 Nm).

Open and close throttle plate and check for proper opera-
tion. Be sure mechanism operates smoothly without
binding or sticking.

HOME

2009 Sportster Service: Fuel System 4-23

sm05425

Throttle position (TP) sensor connector housing

Mounting flange

Figure 4-31. Throttle Position (TP) Sensor Installation (XR

Models)

Install induction module. See

4.11 INDUCTION MODULE:

XR MODELS

Plug TP sensor harness connector [88B] into connector
socket [88A] on TP sensor.

Install airbox assembly and fuel tank. See

4.5 AIRBOX:

XR MODELS

and

4.7 FUEL TANK: XR MODELS

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 fuel hose to fuel pump module. Fill fuel tank and
carefully check for leaks around fuel hose fitting. See

4.7 FUEL TANK: XR MODELS

Plug in main fuse. See

6.38 MAIN FUSE

10. Turn ignition switch on and again check for leaks at the

quick connect fitting and at the induction module.

11. Start vehicle and check for proper throttle operation and

correct idle speed.

HOME

4-24 2009 Sportster Service: Fuel System

4.9

ENGINE TEMPERATURE (ET) SENSOR

GENERAL

See

Figure 4-32

. The engine temperature (ET) sensor is loc-

ated in the top of the rear cylinder head.

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the ET sensor.

sm01635

Figure 4-32. Engine Temperature (ET) Sensor Location

REMOVAL

TOOL NAME

PART NUMBER

TEMPERATURE SENSOR SOCKET

HD-48116-A

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR

MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Remove fuel tank. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

See

Figure 4-33

Figure 4-34

. Disconnect the ET sensor

connector [90] (3) located on right side of H-bracket.

Cut barbed cable strap (2) to free sensor harness from H-
bracket.

XR models: See

Figure 4-34

. Disconnect the breather

hose (1) from the rear cylinder to gain access to the
sensor.

Remove ET sensor as follows:

Attach a universal joint, 6-in. extension and ratchet
to TEMPERATURE SENSOR SOCKET (Part No. HD-
48116-A).

See

Figure 4-35

. Fit engine temperature sensor har-

ness (2) into slot in temperature sensor socket (3).

Slide socket down harness, through square hole in
center of rear rocker cover assembly and fit onto ET
sensor (1).

See

Figure 4-36

. Once you have installed the temper-

ature sensor socket (1) onto the sensor (4), secure
the sensor harness to the socket extension (3) with
tape (6). This will facilitate removal of the sensor.

Remove ET sensor from rear cylinder head.

sm01636

Right wire harness caddy

Barbed cable strap

Sensor harness connector [90]

Harness Loop

Figure 4-33. Engine Temperature Sensor Harness: XL

Models

HOME

2009 Sportster Service: Fuel System 4-25

sm05417

Breather hose

Barbed cable strap

Sensor harness connector [90]

Harness Loop

Figure 4-34. Engine Temperature Sensor Harness: XR

Models

sm01638

ET sensor

Sensor harness

Temperature sensor socket

Figure 4-35. Installing Engine Temperature Sensor Socket

(XL shown)

sm01641

Temperature sensor socket

Universal joint

Socket extension

Engine temperature sensor

Sensor harness

Tape

Figure 4-36. Tape Sensor Harness to Extension (Sensor

Removed from Vehicle for Clarity)

INSTALLATION

See

Figure 4-36

. Fit engine temperature sensor (4) into

temperature sensor socket (1).

NOTE

The next step is very important. The sensor harness MUST be
able to turn with the socket and extension. If it does not, it will
be damaged when the sensor is installed in the cylinder head.

Holding sensor in place in socket, wrap a piece of tape
(6) around sensor harness (5) and socket extension (3).

Slide assembly down into top of rear head and carefully
thread sensor into head. Make sure sensor does not
become cross-threaded. Tighten to 120-168 in-lbs (13.6-
19.0 Nm).

NOTE

See

Figure 4-33

. Make sure there is a loop (4) in sensor har-

ness when securing harness. If harness is pulled tight, it could
be damaged during vehicle operation.

See

Figure 4-33

Figure 4-34

. Use a barbed cable strap

(2) to secure sensor harness. Position cable strap so
harness forms a loop (4) between sensor and cable strap.

Connect sensor connector [90] (3) and secure to caddy.

Install fuel tank and connect fuel supply hose. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR

MODELS

Install main fuse and close left side cover. See

6.38 MAIN

FUSE

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

HOME

4-26 2009 Sportster Service: Fuel System

4.10

INDUCTION MODULE: XL MODELS

GENERAL

The XL model induction module is a side-draft unit with a sep-
arate intake manifold.The induction module includes the throttle
body, fuel injectors, TMAP sensor, TP sensor and IAC.

REMOVAL

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.6 FUEL TANK: XL MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Remove air cleaner cover, air filter and backing plate
assembly. See

4.4 AIR CLEANER: XL MODELS

Remove seat.

Loosen (but do not remove) front fuel tank mounting screw.
Remove rear fuel tank mounting screw, washers and nut.
Carefully pivot rear of fuel tank upward and prop in posi-
tion. See

4.6 FUEL TANK: XL MODELS

See

Figure 4-37

. Remove screw (2) and mounting bracket

(1).

12301

Mounting bracket

Screw

Figure 4-37. Induction Module Mounting Bracket

See

Figure 4-38

. Unplug the following connectors:

front fuel injector (4) connector [84],

rear fuel injector (5) connector [85],

TMAP sensor (6) connector [80],

IAC (7) connector [87],

NOTE

It is important to prevent contaminants from entering the
TPS connectors. Cover both the harness connector and
the TPS connector cavity with tape immediately after dis-
connecting harness.

TP sensor (8) connector [88].

California models only: remove purge hose from fitting
(9) on induction module (1).

HOME

4-28 2009 Sportster Service: Fuel System

12588

Induction module

Intake manifold

Throttle cable bracket

Front fuel injector [84A]

Rear fuel injector [85A]

TMAP sensor [80A]

IAC [87A]

TP sensor [88A]

Purge hose fitting (California models only)

10. Fuel supply hose
11. Throttle wheel
12. Fuel rail

Figure 4-38. Induction Module Assembly (Removed from

Vehicle for Clarity)

See

Figure 4-39

. Slide rubber boot off idle control cable

assembly (1).

10. Loosen jam nut (3).

11. Loosen cable adjuster as far as possible to provide max-

imum slack in idle cable.

10089

Idle control (pull close) cable assembly

Cable adjuster

Jam nut

Figure 4-39. Idle Control Cable Adjustment

12. See

Figure 4-40

. Loosen two screws (2) securing intake

manifold to heads on left side of vehicle, but do not remove
screws.

13. See

Figure 4-41

. Remove two screws (3) securing intake

manifold to heads on right side of vehicle.

14. Pull mounting flanges (4) away from heads as much as

possible and pull induction module and intake manifold
assembly toward the right side, away from vehicle.

12329

Intake manifold

Screw (2)

Figure 4-40. Intake Manifold Mounting Screws: Left Side

HOME

2009 Sportster Service: Fuel System 4-29

12330

Induction module

Intake manifold

Screw (2)

Mounting flange (2)

Figure 4-41. Intake Manifold Mounting Screws: Right Side

15. See

Figure 4-42

. Remove throttle cable (5) from throttle

wheel (7)

Lift throttle cable housing (1) up out of cable guide
(3) in throttle/idle cable bracket (2).

Slide throttle cable (5) out through slot (4) in cable
guide.

Unwind throttle cable from groove in throttle wheel
(7).

Slide cable out through slot (8) and remove throttle
cable barrel (6) from throttle wheel.

12331

Throttle cable housing

Throttle/idle cable bracket

Cable guide

Slot

Throttle cable

Cable barrel

Throttle wheel

Slot

Figure 4-42. Removing/Installing Throttle Cable

16. See

Figure 4-43

. In a similar fashion, remove idle cable

(3) from throttle wheel (6):

Lift idle cable housing (1) and spring (2) up out of
cable guide (7) in throttle/idle cable bracket.

Slide idle cable (3) out through slot in cable guide.

Unwind idle cable from groove in throttle wheel (6).

Slide cable out through slot (5) and remove idle cable
barrel (4) from throttle wheel.

17. Remove induction module and intake manifold from

vehicle.

12332

Idle cable housing

Spring

Idle cable

Cable barrel

Slot

Throttle wheel

Cable guide

Figure 4-43. Removing/Installing Idle Cable

DISASSEMBLY

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

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)

Remove fuel hose, fuel rail and fuel injectors. See

4.17 FUEL INJECTORS

See

Figure 4-44

. Remove screws (1, 2) and cable bracket

(3) from induction module (4).

NOTE

When removing the IAC, the mounting screws MUST be heated
to soften the thread sealant and avoid breakage during removal.
Use ONLY HEAT GUN (Part No. HD-25070) to heat the screws.
NEVER use an open flame.

HOME

4-30 2009 Sportster Service: Fuel System

Remove the following assemblies:

TP Sensor. See

4.8 THROTTLE POSITION (TP)

SENSOR

TMAP sensor. See

4.13 TEMPERATURE MANIFOLD

ABSOLUTE PRESSURE (TMAP) SENSOR

IAC. See

4.12 IDLE AIR CONTROL (IAC)

See

Figure 4-45

. Remove two screws (3) to separate

induction module (1) from intake manifold (2). Discard o-
ring (4).

NOTE

At this level of disassembly, induction module contains no more
serviceable parts. If induction module is determined to be
damaged or defective, replace it.

12689

Screw

Cable bracket

Induction module

Figure 4-44. Removing/Installing Cable Bracket

12336

12337

Induction module

Intake manifold

Screw (2)

O-ring

Groove

Figure 4-45. Induction Module Assembly

ASSEMBLY

See

Figure 4-45

. Place new o-ring (4) into groove (5) in

induction module (1) mating surface.

Mate induction module to intake manifold (2). Secure with
two screws (3). Tighten screws to 35 in-lbs (4.0 Nm).

Install the following assemblies:

TP Sensor. See

4.8 THROTTLE POSITION (TP)

SENSOR

TMAP sensor. See

4.13 TEMPERATURE MANIFOLD

ABSOLUTE PRESSURE (TMAP) SENSOR

IAC. See

4.12 IDLE AIR CONTROL (IAC)

NOTE

Do not install IAC mounting screw on throttle wheel side of
induction module until cable bracket is installed in the next
step. Install other IAC mounting screw but do not tighten at this
time.

See

Figure 4-44

. Install cable bracket (3) onto induction

module (4). Secure with screws (1, 2). Install both screws
finger-tight. Then tighten both IAC mounting screws to 60
in-lbs (6.8 Nm). Tighten side screw (1) to 60 in-lbs (6.8
Nm).

HOME

2009 Sportster Service: Fuel System 4-31

Install fuel injectors, fuel rail and fuel hose. See

INSTALLATION

. Make sure two mounting screws (2) are

screwed into heads two or three turns.

See

Figure 4-46

. Install mounting flanges (1) on intake

manifold (5) with counterbore (2) facing away from mani-
fold and open slotted ends of flanges facing away from
induction module (6) as shown in the figure.

Place a new seal (3) into each mounting flange with the
beveled edge (4) facing the mounting flange counterbore.

NOTE

When induction module is positioned on manifold mounting
screws, be sure the flanges are installed correctly on the
manifold. Also be sure the rubber seals are in place.

See

Figure 4-40

. Place induction module assembly in

position between engine heads. Slide open slotted ends
of mounting flanges under heads of two mounting screws
(2) on left side of engine.

See

Figure 4-41

. Holding induction module/intake manifold

assembly in place, install two mounting screws (3) into
remaining mounting flange holes. Tighten all four screws
finger-tight.

See

Figure 4-37

. Install mounting bracket (1) and screw

(2). Tighten screw finger-tight.

Temporarily install two breather screws through mounting
bracket. Thread breather screws into cylinder heads finger-
tight. This will properly line up induction module assembly.

Tighten screw installed in step 6. to 84-108 in-lbs (9.5-
12.2 Nm).

Tighten all four intake manifold mounting screws to 96-
120 in-lbs (10.9-13.6 Nm).

10. See

Figure 4-43

. Install idle cable barrel (4) into throttle

wheel (6). Slide idle cable (3) through slot (5) and wind
around groove in throttle wheel.

11. Pull cable through slot in cable guide (7). Slide spring (2)

and end of idle cable housing (1) down into cable guide.

12. See

Figure 4-42

. Install throttle cable barrel (6) into throttle

wheel (7). Slide throttle cable through slot (8) and wind
around groove in throttle wheel.

13. Pull cable through slot (4) in cable guide (3). Slide end of

throttle cable housing (1) down into cable guide.

14. Adjust throttle and idle cables. See

1.27 THROTTLE

CONTROL

12333

12335

12334

Mounting flange (2)

Counterbore

Seal (2)

Beveled edge

Intake manifold

Induction module

Figure 4-46. Installing Mounting Flange and Seal

15. California models only: See

Figure 4-47

. Install purge

hose onto fitting (2) on induction module (1).

16. See

Figure 4-48

. Plug in the following connectors:

Front fuel injector (1) connector [84],

Rear fuel injector (2) connector [85],

TMAP sensor (3) connector [80],

IAC (4) connector [87],

TP sensor (5) connector [88].

17. Remove prop from under rear of fuel tank. Lower rear of

fuel tank into position and install screw, washer and nut

HOME

4-32 2009 Sportster Service: Fuel System

in fuel tank rear mounting holes. Tighten front and rear
mounting screws to 15-20 ft-lbs (20.4-27.1 Nm). Install
protective caps on screw ends. See

4.6 FUEL TANK: XL

MODELS

18. Remove breather screws that were temporarily installed

in step 7. Install air cleaner backing plate assembly, air
filter element and air cleaner cover. See

4.4 AIR

CLEANER: XL MODELS

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)

19. Connect fuel hose to fuel pump module. Fill fuel tank and

carefully check for leaks around fuel pump module. See

4.6 FUEL TANK: XL MODELS

20. Install main fuse and close left side cover. See

6.38 MAIN

FUSE

21. Turn Ignition/Light Key Switch to ON and then back to

OFF to reset idle air control to park position.

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

22. Install seat.

23. Road test vehicle.

12610

Induction module

Purge hose (to canister) fitting

Figure 4-47. Purge Hose Fitting (California Models Only)

12588

Front fuel injector [84A]

Rear fuel injector [85A]

TMAP sensor [80A]

IAC [87A]

TP sensor [88A]

Figure 4-48. Induction Module Electrical Connectors

HOME

2009 Sportster Service: Fuel System 4-33

4.11

INDUCTION MODULE: XR MODELS

GENERAL

XR models use a down-draft induction module. The induction
module and intake manifold are incorporated into a one-piece
unit that includes the throttle body, fuel injectors, TMAP sensor,
TP sensor and IAC.

REMOVAL

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.7 FUEL TANK: XR MODELS

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Remove fuel tank and airbox. See

4.7 FUEL TANK: XR

MODELS

and

4.5 AIRBOX: XR MODELS

See

Figure 4-49

. Remove socket head bolts (3), fastener

(1) and fastener (2).

Pull cover away from induction module and disengage
cable retainer from back side of cover. Remove cover.

Disengage throttle cables from induction module. See

2.30 THROTTLE CABLES: ALL MODELS

See

Figure 4-50

. Unplug the following connectors:

front fuel injector (3) connector [84],

rear fuel injector (4) connector [85],

TMAP sensor (5) connector [80],

IAC (6) connector [87],

NOTE

It is important to prevent contaminants from entering the
TPS connectors. Cover both the harness connector and
the TPS connector cavity with tape immediately after dis-
connecting harness.

TP sensor (7) connector [88].

California models: Remove purge hose from fitting (8).

See

Figure 4-51

. Disconnect oil line flare nuts (1) from

flare fittings (2) in cylinder heads. Remove flare fittings (2)
from cylinder heads.

10. Loosen screws that secure induction module to cylinder

heads on left side of vehicle several turns. It is not
necessary to remove them completely.

11. Remove two screws (3) securing induction module to cyl-

inder heads on right side of vehicle.

12. Remove induction module from engine.

sm05419

Fastener, wire form

Fastener, to induction module

Socket head bolts (2)

Figure 4-49. Induction Module Cover

HOME

4-34 2009 Sportster Service: Fuel System

sm04954

Induction module

Throttle cable bracket

Front fuel injector [84A]

Rear fuel injector [85A]

TMAP sensor [80A]

IAC [87A]

TP sensor [88A]

Purge hose fitting (California models only)

Fuel supply hose

10. Throttle wheel
11. Fuel rail (not visible)

Figure 4-50. Induction Module Assembly (Removed from

Vehicle for Clarity)

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Flare nuts

Flare fittings

Fastener

Figure 4-51. Remove Induction Module

DISASSEMBLY

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

See

Figure 4-52

. Remove retainer (7). Remove fuel rail

(8) with hose (4) and injectors (10) from the induction
module.

Remove hose (4) and injectors (10) from fuel rail.

Remove cable bracket (12).

NOTE

Screws (16) MUST be heated to soften the thread sealant and
avoid breakage during removal. Use ONLY HEAT GUN (Part
No. HD-25070) to heat the screws. NEVER use an open flame.

Remove IAC (3). See

4.12 IDLE AIR CONTROL (IAC),

Removal: XR Models

Remove TMAP (15), and TP sensor (1).

Remove mounting flanges (14) and seals (13).

HOME

2009 Sportster Service: Fuel System 4-35

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