Harley Davidson Sportster Models 2009. Service Repair Manual — page 31
NOTES
TORQUE VALUE
FASTENER
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XR
Models
6.8 Nm
60 in-lbs
TMAP sensor screw
4.8 THROTTLE POSITION (TP) SENSOR, Install-
ation: XR Models
3.3 Nm
29 in-lbs
TP sensor mounting screw (XR models)
4.8 THROTTLE POSITION (TP) SENSOR, Install-
ation: XL Models
4.0 Nm
35 in-lbs
TP sensor screw
4.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP) SENSOR, Installation: XL
Models
4.0 Nm
35 in-lbs
TP sensor screw
2009 Sportster Service: Fuel System 4-3
4.2
SPECIFICATIONS: FUEL SYSTEM
SPECIFICATIONS: 2009 SPORTSTER
MODELS
Table 4-1. Capacities: 2009 Sportster 883 Models
XL 883L
LOW
XL 883C
CUSTOM
XL 883
XL 883R
ITEM
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
12.49
3.30 gal.
17.03
4.50 gal.
12.49
3.30 gal.
Fuel tank (total)
2.65
2.80 qt.
2.65
2.80 qt.
2.65
2.80 qt.
Oil tank with filter
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
Transmission (approximate)
3.03
0.80 gal.
3.79
1.00 gal.
3.03
0.80 gal.
Low fuel warning light on
Table 4-2. Capacities: 2009 Sportster 1200 Models
XR 1200
XL 1200N
NIGHTSTER
XL 1200L
LOW
XL 1200R
ROADSTER
XL 1200C
CUSTOM
ITEM
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
LITERS
U.S.
13.25
3.50 gal.
12.49
3.30 gal.
17.03
4.50 gal.
17.03
4.50 gal.
17.03
4.50 gal.
Fuel tank
(total)
2.65
2.80 qt.
2.65
2.80 qt.
2.65
2.80 qt.
2.65
2.80 qt.
2.65
2.80 qt.
Oil tank
with filter
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
0.95
1.00 qt.
Transmission
(approximate)
1.89
0.50 gal.
3.03
0.80 gal.
3.79
1.00 gal.
3.79
1.00 gal.
3.79
1.00 gal.
Low fuel warning
light on
4-4 2009 Sportster Service: Fuel System
4.3
ELECTRONIC FUEL INJECTION (EFI)
TROUBLESHOOTING
See the electrical diagnostic manual for troubleshooting and
diagnostic information.
2009 Sportster Service: Fuel System 4-5
4.4
AIR CLEANER: XL MODELS
REMOVAL
1.
See
. Remove two screws (1) and trim insert
(2) from air cleaner cover (3).
2.
Remove air cleaner cover from air cleaner backplate (10).
Remove air cleaner seal (4) from air cleaner cover.
3.
Remove three screws (5). Remove air filter element (6)
and gasket (7) from air cleaner backplate. Discard gasket.
If filter element is being removed for cleaning only, proceed
to
4.4 AIR CLEANER: XL MODELS, Cleaning, Inspection
which follows.
Install air filter before running engine. Failure to do so can
draw debris into the engine and could result in engine
damage. (00207a)
4.
Remove two breather screws (9) from air cleaner back-
plate.
5.
Remove air cleaner backplate and gasket (11). If snorkel
insert (12) needs to be repaired or replaced, remove it
from air cleaner backplate.
1
2
3
4
5
6
7
8
9
10
11
12
x0242a4x
7.
1.
Filter element gasket
Screw (2)
2.
8.
Trim insert
O-ring (2)
9.
3.
Breather screw (2)
Air cleaner cover
4.
10.
Air cleaner seal
Air cleaner backplate
11.
5.
Backplate gasket
Screw (3)
6.
12.
Air filter element (includes item 7)
Snorkel insert
Figure 4-1. Air Cleaner Assembly
CLEANING, INSPECTION AND REPAIR
1.
See
. Thoroughly clean air cleaner backplate
(10) and inside of air cleaner cover (3).
2.
If air filter element (6) is damaged or if filter media cannot
be adequately cleaned, replace element and proceed to
step 6.
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)
4-6 2009 Sportster Service: Fuel System
3.
Wash air filter element thoroughly in warm, soapy water.
To remove soot and carbon, soak air filter element for 30
minutes in warm water with mild detergent.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
4.
Dry air filter element using low-pressure compressed air.
Rotate air filter element while moving air nozzle up and
down filter element interior. Do not tap air filter element
on hard surface.
5.
Hold air filter element up to strong light source. Element
can be considered sufficiently clean if light is uniformly
visible through filter material.
6.
Examine o-rings (8). If damaged, replace with new o-
ring(s).
7.
Examine air cleaner seal (4). If cracked, torn or otherwise
damaged, replace with new seal.
8.
Repair or replace snorkel insert (12) as necessary.
NOTE
On California models, a gravity operated trap door in the air
cleaner's snorkel is closed when the engine is not running, to
seal the inlet port of the air cleaner backplate. This prevents
hydrocarbon vapors emanating from the induction module
throat from escaping into the atmosphere. When the vehicle
is running, engine vacuum holds the trap door open.
9.
On California models, open the trap door in the snorkel
with a finger, then release. Observe the trap door to make
sure it closes smoothly and completely, without binding.
INSTALLATION
1.
See
. If snorkel insert (12) was removed from
air cleaner backplate, slide insert into air cleaner backplate
and snap into place.
2.
Position new gasket (11) and air cleaner backplate (10)
at induction module air inlet. Secure air cleaner backplate
to engine heads with two breather screws (9). Tighten to
120-144 in-lbs (13.6-16.3 Nm).
3.
Apply a thin coat of engine oil or light grease to o-rings
(8). This will help prevent them from being damaged when
air filter element is installed.
4.
Position new gasket (7) on air cleaner backplate. Make
sure gasket holes are lined up with backplate holes.
5.
Install air filter element (6) onto backplate. Secure with
three screws (5). Tighten to 40-60 in-lbs (4.5-6.8 Nm).
6.
Install air cleaner seal (4) on air cleaner cover (3). To
ensure proper sealing, make sure air cleaner seal covers
the entire edge of the air cleaner cover.
7.
Install air cleaner cover onto backplate. Make sure air
cleaner seal fits inside backplate and is not pinched or
distorted.
8.
Install trim insert (2), and secure insert and air cleaner
cover with two screws (1). Tighten to 36-60 in-lbs (4.1-
6.8 Nm).
2009 Sportster Service: Fuel System 4-7
4.5
AIRBOX: XR MODELS
REMOVAL
1.
Remove the fuel tank. See
.
2.
Disconnect active intake solenoid connector located at
the rear of the airbox.
3.
Lift airbox off induction module, trying to leave the interface
grommet attached to the induction module.
4.
Disconnect crankcase vent hoses from the front and rear
rocker cover fittings and remove airbox assembly from
motorcycle.
5.
Remove filter element as necessary. See
6.
Inspect hoses, interface grommet and housings for
deterioration, cracks, or other damage. Repair or replace
as necessary.
INSTALLATION
1.
See
. Install any hoses that have been removed
from the airbox assembly. Ensure the anchor barb (1) of
the front crankcase vent hose is securely installed in the
hole (2) in the airbox bottom.
2.
If removed, install air filter element and cover. See
3.
See
. If removed, install interface grommet on
induction module. Ensure it is completely seated on the
throat (1) of the induction module.
4.
While holding airbox in approximate installed location,
connect crankcase vent hoses to the fittings (2) on the
front and rear rocker covers. Ensure clamps are in place.
NOTE
It is extremely important that the interface grommet be correctly
and securely installed on the induction module and the airbox.
Failure to do so will result in ingestion of dirt and debris that
would otherwise be caught by the filter element, resulting in
possible decrease of engine life.
5.
Place airbox assembly over interface grommet and work
grommet into airbox opening until securely seated. Edge
of hole in airbox will completely encircle the groove molded
in the grommet when installed correctly.
6.
Mate active air solenoid connector.
7.
Install fuel tank. See
.
2
1
3
sm05088
1.
Anchor barb
2.
Anchor hole in airbox
3.
Vent hose clamp
Figure 4-2. Front Crankcase Vent Hose
2
2
1
sm05090
1.
Induction module throat
2.
Fittings on rocker covers
Figure 4-3. Airbox Connections
4-8 2009 Sportster Service: Fuel System
4.6
FUEL TANK: XL MODELS
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)
NOTE
. Turn the fuel filler cap (2 or 13) clockwise until
at least three clicks are heard in order to verify that it is securely
fastened to the fuel tank (1 or 12).
12
3
13
4
6
10
6
7
8
1
3
2
11
8
7
6
6
5
9
x0089g4x
1.
Fuel tank (XL 883C/XL 1200C/XL 1200L)
2.
Fuel tank filler cap (XL 883C/XL 1200C/XL 1200L)
3.
Gasket
4.
Screw (long)
5.
Screw (short)
6.
Washer (4)
7.
Locknut (2)
8.
Protective cap (2)
9.
Cosmetic cover (2)
10. Ignition coil bracket
11. Console (XL 1200C)
12. Fuel tank (XL 883/XL 883L/XL 883R/XL 1200N/XL 1200R)
13. Fuel tank filler cap (XL 883/XL 883L/XL 883R/XL 1200N/XL 1200R)
Figure 4-4. Fuel Tank and Mounting Hardware
2009 Sportster Service: Fuel System 4-9
PURGING AND DISCONNECTING FUEL
SUPPLY HOSE
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)
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.
Open left side cover. See
.
b.
See
. Remove fuel pump fuse (1) located
in fuse panel in front of battery.
c.
Start engine and allow vehicle to run.
d.
When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.
e.
Shut off ignition and reinstall fuel pump fuse.
Do not thread hex nut onto valve more than two turns to
prevent "bottoming" nut on valve, which can cause a fuel
leak. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00276a)
2.
. Push up on release sleeve (1) on fuel
pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3) from fuel
pump module (4). Immediately clean up any fuel spills.
2
1
12411
1.
Fuel pump fuse
2.
Fuel pump connector [141]
Figure 4-5. Fuel Pump Fuse and Connector
1
2
3
4
12686
1.
Release sleeve (quick-connect fitting)
2.
Fuel supply hose fitting
3.
Fuel supply hose
4.
Fuel pump module
Figure 4-6. Fuel Tank Quick-Connect Fitting
REMOVING FUEL TANK
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse. See
2.
Remove seat.
NOTE
If the fuel tank is being removed only to gain access to items
otherwise hidden, it is not necessary to drain the fuel from the
tank. If the fuel tank is to be disassembled or repaired, follow
the step below to drain the fuel.
3.
Drain fuel tank:
a.
Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.
b.
Position vehicle upright. Remove fuel tank filler cap.
c.
Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.
d.
Direct the pump output into a suitable container.
e.
Pump fuel until fuel tank is empty.
f.
Immediately wipe up any spilled fuel.
4.
. Remove vent hose from fuel tank vent
nipple. Remove cable clip (3) securing fuel pump wiring
harness (2) to mounting boss on H-bracket.
5.
See
. Unplug fuel pump connector (2) [141].
6.
See
. Remove protective caps (8), lock nuts (7),
screws (4, 5) and washers (6) from front and rear of fuel
tank.
7.
Place a clean, soft cloth over front of fuel tank to keep tank
from contacting top fork clamp and damaging paint. Lift
4-10 2009 Sportster Service: Fuel System
up rear of fuel tank. Remove fuel pump harness from clip
on wire harness caddy latch clip on frame backbone.
8.
Lift fuel tank off motorcycle.
9.
Remove fuel pump assembly. See
.
1
3
2
sm01547
1.
Fuel tank vent hose
2.
Fuel pump wiring harness
3.
Cable clip
Figure 4-7. Fuel Tank Vent Hose
CLEANING AND INSPECTION
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)
Extreme caution should be taken when repairing fuel tanks.
Make sure all traces of fuel are purged before making an open
flame repair.
1.
Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.
2.
Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.
3.
Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.
4.
Inspect the fuel tank for leaks or other damage. If a dam-
aged fuel tank cannot be successfully repaired, replace
it.
INSTALLING FUEL TANK
NOTE
Be sure wiring harnesses do not get pinched between fuel tank
and frame during tank installation.
1.
Install fuel pump into fuel tank using new gasket. See
2.
. Position fuel tank on motorcycle. Make
certain that front fuel tank brackets are located outboard
of ignition coil bracket (8).
3.
Place washer (4) on long screw (2). Push screw through
front fuel tank bracket, ignition coil bracket and frame, from
right to left. Place second washer over screw and hand-
start lock nut (5).
8
6
5
4
1
6
5
4
2
3
4
7
x0671a4x
1.
Fuel tank (typical)
2.
Screw (long)
3.
Screw (short)
4.
Washer (4)
5.
Lock nut (2)
6.
Protective cap (2)
7.
Cosmetic cover (2)
8.
Ignition coil bracket
Figure 4-8. Fuel Tank Mounting (Typical)
4.
. Place a clean, soft cloth over front of fuel
tank to keep tank from contacting top fork clamp and
damaging paint. Lift up rear of fuel tank. Place fuel pump
wiring harness (1) into clip on wire harness caddy latch
clip on frame backbone tube. Make sure harness forms a
loop (5) between caddy latch clip and fuel pump module
(6) to avoid pinching harness between fuel tank and frame
backbone tube.
5.
Route fuel pump wiring harness down along left side of
H-bracket. Secure with cable clip (3). Push clip into hole
in mounting boss (2) on H-bracket.
6.
See
. Plug in fuel pump connector (2) [141].
7.
Lower rear of fuel tank into position. See
. Place
washer (4) on short screw (3). Push screw through rear
fuel tank bracket and frame, from right to left. Place second
washer over screw and hand-start lock nut (5).
8.
Tighten both front and rear fuel tank mounting screws to
15-20 ft-lbs (20.4-27.1 Nm). Install protective caps (6) on
screw ends.
9.
See
. Install vent hose onto fuel tank vent nipple.
2009 Sportster Service: Fuel System 4-11
1
3
2
4
5
6
sm01549
1.
Fuel pump wiring harness
2.
Cable clip mounting boss on H-bracket
3.
Cable clip
4.
Wire harness caddy latch clip
5.
Fuel pump wiring harness loop
6.
Fuel pump module
Figure 4-9. Fuel Pump Wiring Harness Routing
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)
1.
See
. 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.
2.
. Install vent hose onto vent nipple on fuel
tank.
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)
3.
Fill fuel tank and carefully inspect for leaks around fuel
pump module.
4.
Install main fuse. See
5.
Turn ignition switch ON and verify fuel pump is activated.
Carefully inspect for leaks at quick-connect fitting. Turn
ignition switch OFF.
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)
6.
Install seat.
VAPOR VALVE
Excessive pressure can build in the fuel tank if vapor valve
is not mounted vertically with long fitting to top. Leaks
due to excessive pressure can cause a fire or explosion,
which could result in death or serious injury. (00265a)
See
. The fuel tank (1) is vented through a stand-
pipe (vent tube) within the tank. A hose (2) at the base of the
fuel tank is connected to the standpipe.
Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)
. The fuel tank vent hose (2) is connected to
a vapor valve (4) located beneath the seat in front of the battery
tray. On non-California models, another hose (5) vents the
vapor valve to the atmosphere. On California models, that hose
is routed to the charcoal canister. See
NOTES
•
See
. Mount the vapor valve (1) in an upright
position with the longer fitting positioned at the top or
excessive fuel vapor pressure may build up within the fuel
tank.
•
See
. Do NOT force vapor valve (1) into clip
(2). Forcing valve in to clip could cause clip to break,
necessitating replacement of entire wiring harness guide
(4).
4-12 2009 Sportster Service: Fuel System
1
2
12387
1.
Fuel tank
2.
Fuel tank-to-vapor valve hose
Figure 4-10. Fuel Tank Venting System
5
4
2
1
3
12327
1.
Battery
2.
Fuel tank-to-vapor valve hose
3.
Vapor valve clip (on wiring harness guide)
4.
Vapor valve
5.
Vapor-valve-to-atmosphere hose (non-California
models)
Figure 4-11. Vapor Valve Assembly
3
4
1
2
12328
1.
Vapor valve
2.
Vapor valve clip
3.
Fuel tank-to-vapor valve hose
4.
Wiring harness guide
Figure 4-12. Vapor Valve Mounting
CONSOLE REPLACEMENT
TOOL NAME
PART NUMBER
CONSOLE ALIGNMENT RING
HD-47114
In addition to the CONSOLE ALIGNMENT RING (Part No. HD-
47114), other special tools are needed:
•
Temporary use of a smaller diameter fuel filler cap (H-D
Part Number 61272-92B). This is the original equipment
cap found on 2004 or later XL 883, XL 883L, XL 883R and
XL 1200R models, as well as many other Harley-Davidson
models.
•
Approximately 18 in. (460 mm) fishing line (or string) to
aid in removing the existing console.
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.
Remove seat.
2.
. Remove the original fuel filler cap (2)
from the fuel tank (1) and set it aside. Obtain a small dia-
meter Harley-Davidson fuel filler cap (5) and screw it into
the fuel filler opening.
3.
See
. Insert the fishing line (2) between the
rear of the fuel tank and the plastic liner (1) on the under-
side of the original console.
2009 Sportster Service: Fuel System 4-13
NOTE
Raise the ends of the fishing line away from the fuel tank to
avoid scuffing the tank finish.
4.
Using a side-to-side "sawing" motion, work the fishing line
toward the front of the fuel tank to break the adhesive bond
between the console and the tank.
5.
Carefully remove the console and liner from the fuel tank
and discard it.
NOTES
•
Be careful not to scratch the paint on the fuel tank when
removing the adhesive.
•
To avoid damaging the fuel tank finish, do not use tools
or abrasive cleaners to remove the adhesive residue that
remains on the fuel tank surface. Try to stay within the
area that will be covered by the new console.
6.
. To remove any adhesive residue
remaining on the fuel tank surface:
a.
Carefully peel off as much adhesive as possible, using
your thumb and fingers only.
NOTE
Use of cleaning compounds other than isopropyl alcohol
may damage fuel tank finish. Test in inconspicuous area.
b.
Clean the top of the fuel tank with a mixture of 50%
to 70% isopropyl alcohol and 30% to 50% distilled
water or, if necessary, straight isopropyl alcohol.
c.
Allow the fuel tank surface to dry thoroughly.
2
3
1
4
5
x0634x7x
1.
Fuel tank
2.
Original equipment fuel filler cap
3.
Fuel tank console
4.
Console alignment ring (Part No. HD-47114)
5.
Small-diameter fuel filler cap
Figure 4-13. Replacing Console: XL 1200C
1
2
12281
1.
Original fuel tank console liner
2.
Fishing line or string
Figure 4-14. Removing Existing Console
10751
Figure 4-15. Removing Adhesive Residue
Installation
1.
. Measure and mark the centerline of the
fuel tank at the rear of the tank.
2.
Obtain the new fuel tank console. Measure and mark the
centerline of the console at the rear of the panel.
3.
. Place CONSOLE ALIGNMENT
RING (Part No. HD-47114) over the fuel filler cap.
4.
Peel the liner from the adhesive backing of the console.
5.
. Position the console over the fuel tank
without touching the adhesive to the tank surface. Center
the large hole over the CONSOLE ALIGNMENT
RING (Part No. HD-47114) tool, and align the mark on the
rear of the console with the mark made on the rear of the
fuel tank.
6.
Slide the front of the console down over the CONSOLE
ALIGNMENT RING (Part No. HD-47114) tool onto the fuel
tank. Bring the rear of the console down, keeping the
marks aligned.
7.
Press the console firmly against the top of the fuel tank
and hold pressure for 30 seconds. After releasing pres-
4-14 2009 Sportster Service: Fuel System
sure, avoid direct contact with the console for about 20
minutes, then remove the CONSOLE ALIGNMENT
RING (Part No. HD-47114) tool.
8.
Remove the small-diameter fuel filler cap and install the
original fuel filler cap.
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)
9.
Install seat.
10. Allow AT LEAST 24 hours after applying the console
before exposing the area to vigorous washing, strong water
spray or extreme weather. The adhesive bond will increase
to maximum strength after about 72 hours at normal room
temperatures.
10752
Figure 4-16. Marking Fuel Tank Centerline
10753
Figure 4-17. Placing Console Alignment Ring Tool (Part
No. HD-47114)
10764
Figure 4-18. Positioning Console on Fuel Tank
2009 Sportster Service: Fuel System 4-15
4.7
FUEL TANK: XR MODELS
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)
PURGING AND DISCONNECTING FUEL
SUPPLY HOSE
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)
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.
Open left side cover. See
.
b.
See
. Remove fuel pump fuse (1) located
in fuse panel in front of battery.
c.
Start engine and allow vehicle to run.
d.
When engine stalls, operate starter for 3 seconds to
remove any remaining fuel from fuel hose.
e.
Shut off ignition and reinstall fuel pump fuse.
2
1
sm04945
1.
Fuel pump fuse
2.
Fuel pump connector [141]
Figure 4-19. Fuel Pump Fuse and Connector
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)
2.
See
. Push up on release sleeve (1) on fuel
pump quick-connect fitting and pull down on fuel supply
hose fitting (2) to disconnect fuel supply hose (3). Immedi-
ately clean up any fuel spills.
1
2
4
3
sm05409
1.
Release sleeve (quick-connect fitting)
2.
Fuel supply hose fitting
3.
Fuel supply hose
4.
Throttle cable retainer
Figure 4-20. Fuel Tank Quick-Connect Fitting
REMOVING FUEL TANK
1.
Purge the fuel supply line of high pressure gasoline. Dis-
connect fuel line from fuel tank. See
MODELS, Purging and Disconnecting Fuel Supply Hose
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse. See
NOTE
If the fuel tank is being removed only to gain access to items
otherwise hidden, it is not necessary to drain the fuel from the
tank. If the fuel tank is to be disassembled or repaired, follow
the steps below to drain the fuel.
4-16 2009 Sportster Service: Fuel System
3.
Drain fuel tank:
a.
Obtain a suitable fuel transfer pump with a long, flex-
ible nozzle.
b.
Position vehicle upright. Remove fuel tank filler cap.
c.
Insert fuel transfer pump nozzle into fuel tank filler
spout. Aim nozzle toward right side of fuel tank to
avoid contacting and damaging fuel pump assembly.
d.
Direct the pump output into a suitable container.
e.
Pump fuel until fuel tank is empty.
f.
Replace fuel tank filler cap.
g.
Immediately wipe up any spilled fuel.
4.
. Remove retainer (4) securing throttle
cables to plate on bottom of fuel tank.
NOTE
See
. Short screws (2) secure trim ring to fuel tank
cover only. It is not necessary to remove these screws unless
either trim ring or fuel tank cover is being replaced.
5.
. Remove four long screws (1) that secure
trim ring (4) and fuel tank cover (5) to fuel tank.
6.
Carefully lift fuel tank cover off fuel tank. Slide cover for-
ward slightly as it is lifted to clear sides of fuel tank.
7.
. Remove vent hose (3) from fuel tank
vent fitting (4). With a gentle twisting motion, pull ground
wire connector [210] (5) straight up off pin on fuel tank
retaining ring (6).
8.
Remove vent hose and ground wire from trough in center
of fuel tank. Pull vent hose and ground wire back out of
the way.
9.
. Unplug fuel pump connector [141] (2).
1
3
1
1
1
2
2
2
2
4
5
sm04947
1.
Screw, long (4)
2.
Screw, short (4)
3.
Fuel cap
4.
Trim ring
5.
Fuel tank cover
Figure 4-21. Fuel Cap and Trim Ring
1
2
3
4
5
6
sm04948
1.
Fuel tank
2.
Fuel cap
3.
Vent hose
4.
Vent fitting
5.
Ground wire connector [210]
6.
Retaining ring
Figure 4-22. Fuel Tank Vent Hose and Ground Wire
10. See
. Remove two screws and washers (3)
securing airbox to bottom of fuel tank.
11. Remove screw with washer (4) from rear of fuel tank.
Remove protective plastic cap (not shown) from threaded
end of screw (6). Remove screw, washers and lock nut.
2009 Sportster Service: Fuel System 4-17
1
2
3
6
4
5
1
sm04952
1.
Fuel tank
2.
Airbox
3.
Screw w/washer (2)
4.
Screw w/washer
5.
Rubber grommet
6.
Screw w/washers and lock nut
Figure 4-23. Fuel Tank and Airbox Mounting Fasteners
12. Lift fuel tank off motorcycle.
NOTE
See
. Metal bushings (4) inside the grommets (3)
may fall when fuel tank is lifted off vehicle. Make sure they do
not fall out and become lost.
13. Remove fuel pump assembly from fuel tank. See
DISASSEMBLE 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)
1.
. Remove filler cap (1) with o-ring (2).
2.
Remove screws (7) and clamp ring (3).
3.
Remove top ring (4).
4.
Remove o-ring (5).
1
2
3
4
5
6
7
sm05448
1.
Filler cap
2.
O-ring
3.
Clamp ring
4.
Top ring
5.
O-ring
6.
Fuel tank
7.
Screw (6)
Figure 4-24. Fuel Tank Assembly
CLEANING AND INSPECTION
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)
Extreme caution should be taken when repairing fuel tanks.
Make sure all traces of fuel are purged before making an open
flame repair.
1.
Clean fuel tank interior with commercial cleaning solvent
or a soap and water solution. Shake fuel tank to agitate
cleaning agent.
2.
Thoroughly flush fuel tank after cleaning. Allow fuel tank
to air dry.
3.
Carefully inspect fuel hose and vent hose for damage,
cuts, cracks, holes, wear or general deterioration. Replace
as necessary.
4-18 2009 Sportster Service: Fuel System
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