Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 20
HOME
FUEL TANK
4.8
NOTE
GENERAL
See Figure 4-11. Turn the fuel filler cap (2 or 13) clockwise
See Figure 4-11. The fuel tank (1 or 12) is a one-piece
until at least three clicks are heard in order to verify that it is
welded tank. Although the tank interior is treated to resist
securely fastened to the fuel tank (1 or 12).
rusting, further protection is required if the motorcycle is to be
placed in storage. Drain the tank completely and apply a one-
to-one oil/fuel mixture (or a commercially available fuel tank
rust preventative) to the tank interior.
x0089d4x
2
11
3
8
7
1
6
6
8
5
13
7
6
12
3
9
6
4
10
1. Fuel tank (XL 883C/XL 1200C)
2. Fuel tank filler cap (XL 883C/XL 1200C)
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 883C/XL 1200C)
12. Fuel tank (XL 883/XL 883L/XL883R/XL 1200R
13. Fuel tank filler cap (XL 883/XL 883L/XL883R/XL 1200R
Figure 4-11. Fuel Tank and Mounting Hardware
2006 Sportster: Fuel System
4-17
HOME
See Figure 4-12. The fuel tank (1) is vented through a stand-
11313
pipe (vent tube) within the tank. A hose (2) at the base of the
fuel tank is connected to the standpipe.
1
1WARNING
Keep vent and vapor valve lines away from exhaust and
2
engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00263a)
See Figure 4-13. The fuel tank vapor hose (2) is connected to
a vapor valve (4) located beneath the seat in front of the bat-
3
tery tray. On non-California models, another hose (5) vents
the vapor valve to the atmosphere. On California models, that
4
hose is routed to the charcoal canister. See 4.9 EVAPORA-
TIVE EMISSIONS CONTROL-CA MODELS.
5
1CAUTION
See Figure 4-14. Mount the vapor valve (1) in an upright
1.
Battery
position with the longer fitting positioned at the top or
2.
Fuel tank-to-vapor valve hose
excessive fuel vapor pressure may build up within the
3.
Vapor valve clip (on wiring harness guide)
fuel tank.
4.
Vapor valve
5.
Vapor-valve-to-atmosphere hose
(non-California models)
CAUTION
Figure 4-13. Vapor Valve Assembly
See Figure 4-14. 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).
11314
3
10665
2
2
4
1
1
1.
Fuel tank
2.
Fuel tank-to-vapor valve hose
Figure 4-12. Fuel Tank Venting System
1.
Vapor valve
2.
Vapor valve clip
3.
Fuel tank-to-vapor valve hose
4.
Wiring harness guide
Figure 4-14. Vapor Valve Mounting
4-18
2006 Sportster: Fuel System
HOME
REMOVAL
CLEANING, INSPECTION AND
REPAIR
1WARNING
Stop the engine when refueling or servicing the fuel sys-
1WARNING
tem. Do not smoke or allow open flame or sparks near
An open flame or spark may cause a fuel tank explosion
gasoline. Gasoline is extremely flammable and highly
if all traces of fuel are not purged from the tank. Use
explosive, which could result in death or serious injury.
extreme caution when servicing fuel tanks. Inadequate
(00002a)
safety precautions may result in death or serious injury.
1WARNING
1
WARNING
A small amount of gasoline may drain from the fuel valve
Use only lead pellets to loosen deposits. Metal balls,
nipple when the fuel hose is disconnected. Thoroughly
such as ball bearings, can cause a spark and explosion,
wipe up any spilled fuel immediately and dispose of rags
which could result in death or serious injury. (00261a)
in a suitable manner. Gasoline can be extremely flamma-
ble and highly explosive. Inadequate safety precautions
1. Clean the tank interior with commercial cleaning solvent
may result in death or serious injury.
or a soap and water solution. Plug fuel tank openings.
Shake the tank to agitate the cleaning agent. If neces-
1.
See Figure 4-9. Turn fuel supply valve
(9) to OFF.
sary, non-ferrous metallic balls or pellets may be added
Remove fuel supply hose (7) and vacuum hose (10) from
to the tank to help loosen deposits.
fuel valve assembly (8). Drain gasoline from tank. See
INSPECTION under 1.26 FUEL SUPPLY VALVE FILTER
NOTE
for the proper procedure.
Be sure to count the number of pellets going into the fuel tank
2.
Remove protective caps (8), locknuts (7), screws (4, 5)
and the number that come out. An extra pellet left in the fuel
and washers (6) from front and rear of fuel tank.
tank could cause fuel delivery problems.
3.
See Figure 4-12. Disconnect fuel tank-to-vapor valve
2. Thoroughly flush the fuel tank after cleaning. Allow tank
hose (2) from fitting at base of fuel tank. Lift fuel tank off
to air dry.
motorcycle.
3. Carefully inspect fuel line and vent lines for damage,
cuts, cracks, holes, wear or general deterioration.
1WARNING
Replace as necessary.
With fuel tank drained, gasoline can spill from bore when
supply valve is loosened or removed. Gasoline is
1WARNING
extremely flammable and highly explosive, which could
Extreme caution should be taken when repairing fuel
result in death or serious injury. Wipe up spilled fuel
tanks. If all traces of fuel are not purged, an open flame
immediately and dispose of rags in a suitable manner.
repair may result in a tank explosion which could result
(00277a)
in death or serious injury.
4.
See Figure 4-9. If the fuel supply valve assembly (8)
4. Inspect the fuel tank for leaks or other damage. If a dam-
requires cleaning or repair, turn the hex fitting (3) coun-
aged fuel tank cannot be successfully repaired, replace
terclockwise to remove the valve assembly from the fuel
it.
tank. See 4.7 FUEL SUPPLY VALVE.
2006 Sportster: Fuel System
4-19
HOME
INSTALLATION
CONSOLE REPLACEMENT
1.
If removed, install fuel supply valve onto fuel tank. See
4.7 FUEL SUPPLY VALVE.
PART NO.
SPECIALTY TOOL
CAUTION
HD-47114
Console Alignment Ring
Be sure that wiring harnesses do not get pinched
between fuel tank and frame during tank installation.
In addition to the CONSOLE ALIGNMENT RING, other spe-
cial tools are needed:
2.
See Figure 4-11. Position fuel tank (1 or 12) on motorcy-
cle. Make certain that front fuel tank brackets are out-
● Temporary use of a smaller diameter fuel filler cap (H-D
board of ignition coil bracket
(10). See Figure
4-12.
Part Number 61272-92B). This is the original equipment
Install fuel tank-to-vapor valve hose (2) onto fitting at
cap found on 2004 or later XL 883, XL 883L, XL 883R
base of fuel tank.
and XL 1200R models, as well as many other Harley-
3.
See Figure 4-11. Secure fuel tank (1 or 12) to vehicle.
Davidson models.
a. Place washer (6) on long screw (4). Push screw
● Approximately 18 in. (0.46 M) fishing line (or string) to aid
through front fuel tank bracket, ignition coil bracket
in removing the existing console.
(10) and frame, from right to left. Place second
washer over screw and hand-start locknut (7).
Removal
b. Place washer on short screw
(5). Push screw
through rear fuel tank bracket and frame, from right
to left. Place second washer over screw and hand-
1WARNING
start locknut.
c. Tighten both screws to 15-20 ft-lbs (20.4-27.1 Nm).
Stop the engine when refueling or servicing the fuel sys-
Install protective caps (8) on screw ends.
tem. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
4.
Connect fuel supply hose to fitting on fuel supply valve
explosive, which could result in death or serious injury.
assembly using a new clamp. Connect vacuum hose to
(00002a)
vacuum nipple on fuel supply valve assembly.
5.
Make sure fuel supply valve is turned OFF. Fill the fuel
1. Remove seat. See REMOVAL under 2.32 SEAT.
tank.
2. See Figure 4-15. Remove the original fuel filler cap (2)
6.
Open the fuel supply valve and carefully inspect for
from the fuel tank (1) and set it aside. Obtain a small
leaks. Turn the fuel supply valve OFF after the inspection
diameter Harley-Davidson fuel filler cap (5) and screw it
is performed.
into the fuel filler opening.
x0634x7x
2
3
1
4
5
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 4-15. Replacing Console-
Sportster Custom Models
4-20
2006 Sportster: Fuel System
HOME
3.
See Figure 4-16. Insert the fishing line (2) between the
10750
rear of the fuel tank and the plastic liner (1) on the under-
side of the original console.
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 adhe-
sive bond between the console and the tank.
2
5.
Carefully remove the console and liner from the fuel tank
1
and discard it.
1.
Original fuel tank console liner
CAUTION
2. Fishing line or string
Be careful not to scratch the paint on the fuel tank when
removing the adhesive.
Figure 4-16. Removing Existing Console
NOTE
To avoid damaging the fuel tank finish, do not use tools or
abrasive cleaners to remove the adhesive residue that
10751
remains on the fuel tank surface. Try to stay within the area
that will be covered by the new console.
6.
See Figure
4-17. 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.
1WARNING
Observe warnings on labels of cleaning compounds.
Failure to follow warnings could result in death or seri-
ous injury. (00076a)
CAUTION
Use of cleaning compounds other than isopropyl alcohol
Figure 4-17. Removing Adhesive Residue
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.
2006 Sportster: Fuel System
4-21
HOME
5. See Figure 4-20. Position the console over the fuel tank
Installation
without touching the adhesive to the tank surface. Center
1.
See Figure 4-18. Measure and mark the centerline of the
the large hole over the CONSOLE ALIGNMENT RING
fuel tank at the rear of the tank.
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
10752
ALIGNMENT RING 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-
sure, avoid direct contact with the console for about 20
minutes, then remove the CONSOLE ALIGNMENT
RING tool.
8. Remove the small-diameter fuel filler cap and install the
original fuel filler cap.
9. Install seat. See INSTALLATION under 2.32 SEAT.
1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat can
Figure 4-18. Marking Fuel Tank Centerline
shift causing loss of control, which could result in death
or serious injury. (00070a)
2.
Obtain the new fuel tank console. Measure and mark the
centerline of the console at the rear of the panel.
10. Allow AT LEAST 24 hours after applying the console
before exposing the area to vigorous washing, strong
3.
See Figure 4-19. Place CONSOLE ALIGNMENT RING
water spray or extreme weather. The adhesive bond will
over the fuel filler cap.
increase to maximum strength after about 72 hours at
normal room temperatures.
10753
10764
Figure 4-19. Placing Console Alignment Ring Tool
(Part No. HD-47114)
4.
Peel the liner from the adhesive backing of the console.
Figure 4-20. Positioning Console on Fuel Tank
4-22
2006 Sportster: Fuel System
HOME
EVAPORATIVE EMISSIONS CONTROL-CA MODELS
4.9
● When the engine is running, carburetor venturi negative
GENERAL
pressure (vacuum) slowly draws off the hydrocarbon
vapors from the charcoal canister through the canister-
Harley-Davidson motorcycles sold in the state of California
to-carburetor purge hose (8). These vapors pass through
are equipped with an evaporative (EVAP) emissions control
the carburetor and are burned as part of normal combus-
system. The EVAP system prevents fuel hydrocarbon vapors
tion in the engine. The large diameter canister-to-air
from escaping into the atmosphere and is designed to meet
cleaner hose (canister clean air inlet hose) supplies the
the California Air Resource Board
(CARB) regulations in
canister with fresh air from the air cleaner.
effect at the time of manufacture.
See Figure 4-21. The EVAP functions in the following man-
1WARNING
ner:
Keep vent and vapor valve lines away from exhaust and
●
Hydrocarbon vapors in the fuel tank (3) are directed
engine. Gasoline is extremely flammable and highly
through the vapor valve (4) and stored in the charcoal
explosive, which could result in death or serious injury.
canister (5). If the vehicle is tipped at an abnormal angle,
(00263a)
the vapor valve closes to prevent liquid gasoline from
leaking out of the fuel tank into the charcoal canister
NOTE
through the vapor valve hoses (6, 7).
The EVAP system has been designed to operate with a mini-
●
When the engine is not running, the gravity operated trap
mum of maintenance. Check that all hoses are properly con-
door in the air cleaner’s snorkel (10) is closed to seal the
nected, are not pinched, kinked, cracked or torn, and are
inlet port of the air cleaner backplate. This prevents
routed properly. Improper connections could leak charcoal
hydrocarbon vapors emanating from the carburetor
from canister.
throat and from the float bowl overflow (vent) hose (12)
from escaping into the atmosphere.
1. Air cleaner backplate
x0244b4x
2. Carburetor
3. Fuel tank
3
4. Vapor valve
5. Charcoal canister
6. Fuel tank-to-vapor valve hose
7. Vapor valve-to-canister hose
8. Purge hose
9. Canister clean air inlet hose
10. Snorkel with trap door
11. Fuel valve
12. Overflow (vent) hose
13. Vacuum hose
6
9
4
1
8
11
13
7
2
12
5
10
Figure 4-21. California Evaporative Emissions Control System
2006 Sportster: Fuel System
4-23
HOME
REMOVAL
x0088a4x
3
Charcoal Canister
1
1.
See Figure 4-22. Charcoal canister is mounted to a
bracket attached to rear brake master cylinder bracket,
near bottom of frame in front of rear fork pivot point.
4
Remove two screws (1) and canister guard (2).
2
2.
Mark the three hoses connected to charcoal canister (6).
Disconnect hoses from canister.
3.
Depress locking tabs at left end of canister clip (5). Slide
5
canister towards left side of vehicle until it disengages
8
10
from canister clip.
4.
Remove two screws (7) and washers (8) to detach canis-
7
ter clip from canister mounting bracket (3).
1WARNING
Direct contact of D.O.T. 5 brake fluid with eyes can cause
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
and get medical attention. Swallowing large amounts of
D.O.T. 5 brake fluid can cause digestive discomfort. If
6
9
11
swallowed, obtain medical attention. Use in well venti-
lated area. KEEP OUT OF REACH OF CHILDREN.
1.
Screw (2)
(00144a)
2.
Canister guard
5.
If canister mounting bracket requires repair/replacement,
3.
Canister mounting bracket
proceed as follows:
4.
Screw (2)
5.
Canister clip
a. Drain rear master cylinder reservoir and detach res-
6.
Charcoal canister
ervoir hose from rear master cylinder. See
2.13
7.
Screw (2)
REAR BRAKE MASTER CYLINDER RESERVOIR.
8.
Washer (2)
b. Remove two screws (4) to detach canister mounting
9.
Clean air hose from air cleaner backplate
bracket from rear master cylinder mounting bracket.
10.
Purge hose from carburetor
11.
Vent hose from vapor valve
Figure 4-22. Charcoal Canister Mounting
4-24
2006 Sportster: Fuel System
HOME
Vapor Valve
INSTALLATION
NOTE
See Figure 4-23. The vapor valve (2) is located beneath the
1WARNING
seat in front of the battery (6), in a clip (4) molded into frame-
Direct contact of D.O.T. 5 brake fluid with eyes can cause
mounted wiring harness guide (7).
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
1.
Open left side cover. No tools are required. See 1.6
and get medical attention. Swallowing large amounts of
LEFT SIDE COVER.
D.O.T. 5 brake fluid can cause digestive discomfort. If
2.
See Figure 4-23. Carefully remove vapor valve (2) from
swallowed, obtain medical attention. Use in well venti-
clip (4).
lated area. KEEP OUT OF REACH OF CHILDREN.
(00144a)
3.
Mark two hoses (1, 3) connected to upper and lower fit-
tings of vapor valve. Remove hoses from fittings.
Vapor Valve
1WARNING
x0590a4x
Keep vent and vapor valve lines away from exhaust and
engine. Gasoline is extremely flammable and highly
To fuel
explosive, which could result in death or serious injury.
tank
(00263a)
CAUTION
1
See Figure 4-23. Mount the vapor valve (2) in an upright
position with the longer fitting positioned at the top or
excessive fuel vapor pressure may build up within the
fuel tank. Mounting the vapor valve upside down will
2
result in fuel flow problems.
1. See Figure 4-23. Hold vapor valve (2) in an upright posi-
tion with the long necked end pointing up. Insert top fit-
ting of vapor valve into fuel tank-to-vapor valve hose (1).
3
Install bottom vapor valve fitting into vapor valve-to-can-
ister hose (3).
To charcoal
2. Push body of vapor valve into clip (4) molded into frame-
canister
mounted wiring harness guide (7) on left side of vehicle,
in front of battery.
11313
1
6
CAUTION
See Figure 4-23. Do NOT force vapor valve (2) into clip
(4). Forcing valve in to clip could cause clip to break,
necessitating replacement of entire wiring harness guide
7
(7).
NOTE
See Figure 4-23. On non-California models, charcoal canister
is absent and bottom hose (3) of vapor valve (2) is vented to
the atmosphere.
4
3. Close left side cover.
2
5
3
1.
Fuel tank-to-vapor valve hose
2.
Vapor valve
3.
Vapor-valve-to-canister hose
4.
Vapor valve clip
5.
Canister-to-carburetor purge hose
6.
Battery
7.
Wiring harness guide
Figure 4-23. Vapor Valve and Hose Routing - California
2006 Sportster: Fuel System
4-25
HOME
Charcoal Canister
d0112x4x
1.
See Figure 4-22. If canister mounting bracket (3) was
1
removed, proceed as follows:
a. Attach bracket to rear master cylinder mounting
bracket and frame with two screws (4). Tighten to
17-22 ft-lbs (23.1-29.9 Nm).
b. Attach rear master cylinder reservoir feed hose to
rear master cylinder feed hose port fitting.
c. With motorcycle upright, fill reservoir with Harley-
2
Davidson D.O.T. 5 BRAKE FLUID until the fluid level
reaches the UPPER mark on the reservoir. See 2.13
REAR BRAKE MASTER CYLINDER RESERVOIR.
d. Bleed rear brake system. See BLEEDING REAR
BRAKE under 1.9 BLEEDING HYDRAULIC BRAKE
SYSTEM.
2.
Attach canister clip (5) to canister mounting bracket with
two screws (7) and two washers (8). Tighten to 36-60 in-
lbs (4.1-6.8 Nm).
3.
Starting at left side of canister clip, slide charcoal canis-
ter (6) to the right until tabs on canister clip lock canister
in place. Bend tabs outward somewhat if canister is not
held securely.
3
4.
See Figure 4-24. Connect three marked hoses to their
1.
Purge hose from carburetor
proper fittings on canister.
2.
Vent hose from fuel tank and vapor valve
3.
Clean air hose from air cleaner backplate
5.
See Figure 4-22. Install canister guard (2) using two
screws (1). Tighten to 35-45 in-lbs (4.0-5.1 Nm).
Figure 4-24. Charcoal Canister Connections
4-26
2006 Sportster: Fuel System
HOME
3. See Figure 4-27. Route fuel tank-to-vapor valve hose (2)
HOSE ROUTING
forward along left side of frame backbone, crossing over
to right side and connect to fitting on bottom of fuel tank
See Figure 4-21., California Evaporative Emissions Control
(1).
System schematic, and then see Canister Hose Routings.
4. Route canister-to-carburetor purge hose up right side of
Carburetor
frame rear downtube. Secure to wiring harness with a
cable strap. Continue routing hose forward along right
See Figure 4-25. Route the evaporative emissions control
side of frame backbone tube, over rear cylinder head and
hoses at the carburetor as shown. To gain access to the
down, connecting hose to carburetor vacuum fitting.
hoses, remove the fuel tank and/or air cleaner/backplate
5. Secure hoses to frame backbone above rear cylinder
assembly if necessary.
head with a cable strap.
x0245a4x
2
11492
3
2
1
1
3
1.
Overflow (vent) hose (to air cleaner backplate)
1.
Canister-to-air cleaner hose
2.
Purge hose (to canister)
2.
Four-hose clip
3.
Carburetor
3.
Charcoal canister
Figure 4-25. Emissions Hose Routing at Carburetor
Figure 4-26. Canister-to-Air Cleaner Hose
(Vehicle Partially Disassembled for Clarity)
Canister Hose Routings
1.
See Figure 4-26. Connect one end of canister-to-air
cleaner hose (canister clean air inlet hose) (1) to fitting
10665
on right side of charcoal canister (3). Route hose straight
up, over rear end of engine crankcase, through bottom
2
slot of four-hose clip (2), along top of sprocket cover,
gear case cover, and up to air cleaner backing plate.
2.
See Figure 4-23. Connect vapor valve-to-canister hose
(3) and canister-to-carburetor purge hose (5) to labeled
1
fittings on left side of charcoal canister. Route both hoses
up behind rear brake reservoir hose, between rear fork
pivot point and rear end of crankcase. Connect vapor
valve-to-canister hose to bottom of vapor valve (2). Con-
nect fuel tank-to-vapor valve hose (1) at top of vapor
1.
Fuel tank
valve.
2.
Fuel tank-to-vapor valve hose
Figure 4-27. Fuel Tank-to Vapor Valve Hose Routing
2006 Sportster: Fuel System
4-27
HOME
INTAKE LEAK TEST
4.10
GENERAL
11479
9
8
1DANGER
Propane is an extremely flammable liquid and vapor.
Vapor may cause flash fire. Keep away from heat, sparks
7
and flame. Keep container closed. Use only with ade-
quate ventilation. Failure to follow this alert can result in
death or serious injury.
1WARNING
Read all directions and warnings on propane bottle. Fail-
6
ure to follow all directions and warnings on bottle could
result in death or serious injury.
NOTES
● To prevent false readings, keep air cleaner cover
installed when performing test.
5
● Do not direct propane into air cleaner; false readings will
result.
LEAK TESTER
1
Parts List
2
4
● Standard 14 oz. propane cylinder.
● Propane Enrichment Kit (Part No. HD-41417).
Tester Assembly
3
1.
See Figure 4-28. Make sure valve knob (6) is closed
(fully clockwise).
2.
Screw valve assembly (5) onto propane bottle (1).
1.
Propane bottle
2.
Nozzle
Tester Adjustment
3.
Copper tube
1.
See Figure 4-28. Press and hold trigger button (8).
4.
Hose
5.
Valve assembly
2.
Slowly open valve knob (6) until pellet in flow gauge (7)
6.
Valve knob
rises to between 5 and 10 SCFH on gauge.
7.
Flow gauge
3.
Release trigger button.
8.
Trigger button
9.
Hanger
Figure 4-28. Leak Tester
4-28
2006 Sportster: Fuel System
HOME
PROCEDURE
11482
1.
Start engine.
2.
Warm up engine to operating temperature.
1DANGER
Propane is an extremely flammable liquid and vapor.
3
Vapor may cause flash fire. Keep away from heat, sparks
and flame. Keep container closed. Use only with ade-
quate ventilation. Failure to follow this alert can result in
death or serious injury.
NOTE
Do not direct propane stream toward air cleaner. If propane
2
enters air cleaner, a false reading will be obtained.
3.
See Figure 4-29. Aim nozzle (3) toward possible sources
of leak such as intake manifold mating surfaces.
4.
Press and release trigger button (2) to dispense pro-
pane. Tone of engine will change when propane enters
source of leak. Repeat as necessary to detect leak.
5.
When test is finished, close valve knob (turn knob fully
1
clockwise).
1.
Propane bottle
2.
Trigger button
3.
Nozzle
Figure 4-29. Checking for Leaks
2006 Sportster: Fuel System
4-29
HOME
NOTES
4-30
2006 Sportster: Fuel System
HOME
SPECIFICATIONS
5.1
Table 5-1. Starter
Table 5-2. Service Wear Limits
ITEM
SPECIFICATION
ITEM
IN.
MM.
Free (no load) speed
3000 RPM (min.) @ 11.5 V
Brush length (minimum)
0.443
11.0
Free (no load) current
90 amp (max.) @ 11.5 V
Commutator runout
0.016
0.41
Stall torque
8.1 ft-lbs (11.0 Nm) (min.) @ 2.4 V
Commutator diameter (minimum)
1.141
28.98
Commutator mica depth (minimum)
0.008
0.203
2006 Sportster: Starter
5-1
HOME
TORQUE VALUES
5.2
ITEM
TORQUE
NOTES
Exhaust pipe clamp bracket
30-33 ft-lbs
40.7-44.8 Nm
page 5-14
screw
Field wire terminal nut
70-90 in-lbs
7.9-10.2 Nm
page 5-11
Sprocket cover screw
80-120 in-lbs
9.0-13.6 Nm
page 5-14
Starter mounting bolt
13-20 ft-lbs
17.6-27.1 Nm
page 5-12
Starter positive terminal nut
60-85 in-lbs
6.8-9.6 Nm
page 5-12
Starter through bolt
39-65 in-lbs
4.4-7.4 Nm
page 5-11
5-2
2006 Sportster: Starter
HOME
ELECTRIC STARTER SYSTEM
5.3
GENERAL
OPERATION
The starter is made up of an armature, field winding assem-
See Figure 5-2. The starter relay is activated when the starter
bly, solenoid, drive assembly, idler gear and drive housing.
switch is pushed. This activates the starter solenoid, allowing
battery current to flow into the pull-in winding (10) and also
The starter motor torque is increased through gear reduction.
into the hold-in winding (11) to ground.
The gear reduction consists of the drive pinion on the arma-
ture, an idler gear and a clutch gear in the drive housing. The
The magnetic forces of the pull-in and hold-in windings in the
idler gear is supported by rollers. The clutch gear is part of
solenoid push the plunger (7) causing it to shift to the left.
the overrunning clutch/drive assembly.
This action engages the pinion gear (1) with the clutch ring
gear (13). At the same time, the main solenoid contacts (8)
The overrunning clutch is the part which engages and drives
are closed, so battery current flows directly through the field
the clutch ring gear. It also prevents the starter from overrun-
windings (3) to the armature (4) and to ground. Simulta-
ning. The field windings are connected in series with the
neously, the pull-in winding is shorted.
armature through brushes and commutator segments.
The current continues flowing through the hold-in winding
Wiring Diagram
keeping the main solenoid contacts closed. At this point, the
starter begins to crank the engine.
See Figure 5-1. The starting circuit wiring diagram contains
information about wiring configuration. For additional informa-
After the engine has started, the pinion gear turns freely on
tion concerning the starting system circuit, see the wiring dia-
the pinion shaft through the action of the overrunning clutch
grams in Appendix B.
(12). The overrunning clutch prevents the clutch ring gear
(13) (which is now rotating under power from the engine) from
Starter Relay
turning the armature too fast.
The starter relay is a non-repairable part that must be
When the starter switch is released, the current of the hold-in
replaced if it fails. See 7.26 SYSTEM FUSES AND STARTER
winding is fed through the main solenoid contacts and the
RELAY for starter relay location and replacement procedure.
direction of the current in the pull-in winding is reversed. The
solenoid plunger is returned to its original position by the
return spring, which causes the pinion gear to disengage
from the clutch ring gear.
2006 Sportster: Starter
5-3
HOME
xd0023xxx
Starting 1 of 1
BATTERY
IGNITION SWITCH LEGEND
BK
HAND CONTROLS,
RIGHT
SWITCH
RED/BLACK
RED
RED/GRAY
POSITION
[162]
OFF
ACC.
IGNITION
DOT INDICATES CONTINUITY WITH RED
RIGHT TURN SWITCH
WIRE IN SWITCH POSITION INDICATED
ENGINE STOP/RUN SWITCH
START SWITCH
IGN
30 AMP
STOPLIGHT SWITCH
MAXIFUSE
SWITCH
[33]
[5B]
[22B]
STARTER
6 5 4
3
2
1
B A
6
5
4 3
2
1
[22A]
R
[61B]
IGNITION - 15A
A
B
[30A]
[30B]
GY
GY
R/BK
BATTERY
1
1
BN/GY
IGNITION
2
2
GY
VSS / SERIAL DATA LINK
3
3
SECURITY INDICATOR
4
4
LEFT TURN FEED
5
5
RIGHT TURN FEED
6
6
TURN SIGNAL/
RIGHT TURN SWITCH INPUT
7
7
SECURITY MODULE
LEFT TURN SWITCH INPUT
8
8
START RELAY CONTROL
9
9
TN/GN
IGNITION ENABLE SIGNAL
10
10
ALARM SIGNAL
11
11
BATTERY - 15A
J
I
GROUND
12
12
BK
BN/GY
R
TS/TSSM
[62A]
4
5 1 2 3
T
K U S E
[62B]
BK/R
R/BK
TN/GN
POWERTRAIN
GN
GROUND
POINT
PIN CONNECTOR
(A side)
START RELAY
ACCESSORY
IGNITION
D
C B
A
[GND1]
15A
15A
SOCKET CONNECTOR
E
BATTERY
INSTRUMENTS
(B side)
J
I
H
G
K
15A
15A
LIGHTS
SPARE
R
P
O
M
U T S
15A
[61] TOP VIEW
Figure 5-1. Starting Circuit Schematic
5-4
2006 Sportster: Starter
HOME
d0630x5x
4
5
3
6
Starter at instant
starter switch is closed
2
1
7
8
10
11
12
13
9
Starting circuit-see
wiring diagram
4
5
3
6
Starter during
cranking
2
1
7
8
1.
Pinion gear
2.
Idler gear
11
10
12
3.
Field winding
4.
Armature
13
5.
Brush
6.
Ball bearing
7.
Solenoid plunger
8.
Main solenoid contacts
9.
Battery
9
10. Pull-in winding
Starting circuit-see
11. Hold-in winding
wiring diagram
12. Overrunning clutch
13. Clutch ring gear
Figure 5-2. Starter Operation
2006 Sportster: Starter
5-5
HOME
STARTER MOTOR
5.4
REMOVAL
11501
1WARNING
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) bat-
tery cable at engine and then positive (+) cable from bat-
tery. (00280a)
1.
Remove negative (-) battery cable from stud on engine
crankcase boss behind starter motor assembly. See 1.7
BATTERY MAINTENANCE.
2.
Open left side cover. No tools are required. See 1.6
LEFT SIDE COVER.
3.
Remove positive (+) battery cable from battery positive
(+) terminal. See 1.7 BATTERY MAINTENANCE.
4.
Close left side cover.
5.
Drain transmission lubricant and remove primary cover.
See Primary Cover REMOVAL under 6.3 PRIMARY
CHAIN ADJUSTER.
6.
Remove rear muffler and exhaust pipe. See
2.27
EXHAUST SYSTEM.
Figure 5-3. Starter Mounting Bolts
7.
Remove positive (+) battery lead and solenoid wire from
starter.
NOTE
A ball hex driver may be required to gain access to the starter
mounting bolts.
8.
See Figure 5-3. Remove the two starter mounting bolts
and washers.
9.
Remove starter and gasket from right side of motorcycle.
5-6
2006 Sportster: Starter
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