Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 28
540
SUPPLEMENT
68
FUEL TANK-FUEL INJECTED MODELS (2004-ON)
1. Vent hose-
fuel tank-to-vapor
valve
2. Bolt
3. Filter cap
4. Gasket
5. Washer
6. Clip
7. Acorn nut
8. Fuel tank
9. Check valve and
fuel strainer
10. Fuel line
11. Acorn nut
12. Hose clamp
13. Crossover hose
14. Vent hose- vapor
valve-to-atmosphere
15. Clip
16. Vapor valve
11. Drain any remaining fuel left in the tank into a gas
FUEL TANK
can.
(2004-ON FUEL INJECTED MODELS)
12. Installation is the reverse of these steps. Note the
following:
WARNING
a. Tighten the front and rear bolts and nuts to
Some fuel may spill from the fuel tank
15-20 ft.-lbs. (20-27 N•m).
hose when performing this procedure.
Because gasoline is extremely flam-
b. Reconnect the fuel hose to the fuel valve and se-
mable and explosive, perform this
cure it with a new hose clamps.
procedure away from all open flames
(including appliance pilot lights) and
c. Connect the crossover hose and secure it with a
sparks. Do not smoke or allow anyone
new hose clamps.
to smoke in the work area, as an ex-
d. Refill the tank and check for leaks.
plosion and fire may occur. Always
2002-2005 MODEL SERVICE INFORMATION
541
5. Disconnect the drain hose and reinstall the plug
69
into one end of it.
6. Repeat for the other side of the fuel tank.
7. Plug the fuel tank crossover fittings to prevent the
draining of fuel.
Removal/Installation
The crossover fuel hose is secured to the fuel tank
with non-reusable clamps. If the same type of clamps
are going to be reinstalled, purchase new ones before
servicing the fuel tank.
Refer to Figure 68.
70
1. Depressurize the fuel system as described under
Depressurizing The Fuel System in this Supplement.
2. Remove the seat as described in Chapter Thirteen.
NOTE
On models so equipped, always disarm
the optional TSSM security system
prior to disconnecting the battery or the
siren will sound.
3. Disconnect the battery negative cable as described
in Chapter Eight.
work in a well-ventilated area. Wipe
4. Remove the fuel tank console as described in this
up any spills immediately.
section.
WARNING
5. Disconnect the fuel pump electrical connector on
Make sure to route the fuel tank vapor
fuel tank top plate.
hoses so that they cannot contact any
hot engine or exhaust component.
WARNING
These hoses contain flammable vapors.
A small amount of fuel will drain out of
If a hose melts from contacting a hot
the fuel tank when the fuel line is dis-
part, leaking vapors may ignite, caus-
connected from the base of the tank.
ing a fire.
Place several shop cloths under the fuel
14
line fitting to catch any spilled fuel prior
to disconnecting it. Discard the shop
Fuel Tank Draining
cloths in a suitable safe manner.
1. Depressurize the fuel system as described under
6. Pull up the chrome sleeve on the fuel line quick
Depressurizing The Fuel System in this section.
disconnect fitting (Figure 69) and disconnect the fuel
2. Make a drain hose from 5/16 in. inner diameter
supply line from the fuel tank.
hose and plug one end of it. Make it long enough to go
7. Disconnect the crossover hose (Figure 70) from
from the fuel tank crossover hose fitting to a gas can.
one of the fittings on the fuel tank. Drain the fuel tank
3. Disconnect the crossover hose from one of the fit-
as in this section.
tings on the fuel tank. Immediately connect the drain
8. Disconnect the vent hose from the fuel tank.
hose made in Step 2 to the fuel tank fitting.
4. Place the plugged end of the drain hose into the gas
9. Remove the front and rear bolts, washers and acorn
can and remove the plug. Drain the fuel from that side
nuts securing the fuel tank to the frame.
of the fuel tank.
10. Lift off and remove the fuel tank.
542
SUPPLEMENT
NOTE
an inaccurate reading and must be re-
Store the fuel tank in a safe place away
placed.
from open flames or where it could be
damaged.
11. Carefully remove the top plate and sending unit
while moving it back and forth and while lifting and
11. Drain any remaining fuel left in the tank into a gas
turning it in either direction.
can.
12. Remove the gasket from the fuel tank and discard
12. Installation is the reverse of these steps. Note the
it.
following:
13. To remove the fuel level sender from the top
a. Tighten the front and rear bolts and nuts to
plate, move the locking tab toward the rear of the top
15-20 ft.-lbs. (20-27 N•m).
plate and disengage the sender from the top plate. Re-
b. Reconnect the fuel line quick disconnect fitting
move the sender from the top plate.
(Figure 69) onto the fuel tank until it clicks into
14. Install by reversing these removal steps. Note the
the locked position. Pull down on the fuel line
following:
to make sure it is secured to the fitting.
a. Install a new gasket between the top plate and
c. Refill the tank and check for leaks.
the fuel tank. Do not apply any type of sealant
to the gasket.
FUEL TANK TOP PLATE AND
b. Use new T20 Torx screws and tighten in a
FUEL GAUGE SENDING UNIT
crisscross pattern to 20 in.-lb. (2.3 N•m).
(2004-ON ALL MODELS)
c. Refill the tank and check for leaks.
Refer to Figure 71.
1. On fuel injected models, depressurize the fuel sys-
FUEL PUMP AND FUEL FILTER
tem as described in this chapter section.
(2004-ON FUEL INJECTED MODELS)
2. Remove the seat as described in Chapter Thirteen.
3. Drain the fuel tank as described in this
Refer to Figure 72.
Supplement.
4. Remove the fuel tank console as described in this
section.
Fuel Pump and Fuel Filter
5. On models so equipped, remove the fuel level
Removal/Installation
gauge as described in this section.
6A. On carbureted models, disconnect the electrical
1. Remove the top plate assembly as previously de-
connector from the top plate of the fuel level sender
scribed in this section.
unit.
2. Depress the tab and disconnect the fuel hose from
6B. On fuel injected models, disconnect the electrical
the fuel pump assembly.
connector from the top plate of the fuel pump/sender.
3. Disconnect the electrical connector from the fuel
7. Disconnect the fuel tank vent hose from the top plate.
pump assembly.
8. Remove the T20 Torx screws securing the top
4. Lift up on the fuel pump assembly tab, push the as-
plate to the fuel tank. Discard the screws as they can-
sembly toward the front of the fuel tank and disengage
not be reused.
it from the fuel tank.
9. Rotate the top plate toward the right side until the
5. Rotate the fuel pump assembly clockwise and up-
vent tube clears the fuel tank opening.
ward. Carefully remove the assembly from the left
10. On fuel injected models, perform he following:
side of the fuel tank opening.
a. Depress the tab and remove the fuel
6. Install by reversing these removal steps. Note the
pump/sender wiring from the top plate.
following:
b. Disconnect the wire harness from the fuel
a. Install a new O-ring on the fuel hose where it
pump.
connects to the fuel pump assembly.
CAUTION
b. Push the fuel hose onto the assembly until it
Do not bend the arm during removal of
clicks into the locked position. Pull on the fuel
the sending unit. If bent, it will result in
hose to make sure it is secured to the fitting.
2002-2005 MODEL SERVICE INFORMATION
543
71
FUEL TANK TOP PLATE-ALL MODELS (2004-ON)
14
1. Screw
2. Wiring harness
3. Filler cap
4. Gasket
5. Top plate (FXD, FXDI, FXDX,
FXDXI, FXDC, FXDCI)
6. Fuel restrictor
7. Gasket
8. Connector
9. Fuel level sending unit
10. Top plate (FXDWG, FXDWGI)
11. Gasket
12. Top plate (FXDL, FXDLI)
544
SUPPLEMENT
72
FUEL PUMP AND FILTER-FUEL INJECTED MODELS
(2004-ON)
1. Connector
2. Wiring harness
3. Regulator
4. O-ring
5. Regulator ring
6. Upper retainer
7. Fuel filter
8. O-ring
9. Filter housing
10. Fuel level sending unit
11. Wiring harness
12. Upper insulator
13. Fuel pump
14. Lower insulator
15. Lower retainer
16. Inlet strainer
2002-2005 MODEL SERVICE INFORMATION
545
Fuel Filter Replacement
2. Depress the tabs on the fuel inlet strainer and re-
move the strainer from the fuel pump and the lower re-
1. Remove the fuel pump and fuel filter assembly as
tainer.
previously described.
3. Install a new inlet strainer onto the fuel pump inlet
2. Depress the tabs on fuel filter housing and separate
receptacle and onto the lower retainer.
the end cap from the fuel filter housing.
4. Push the inlet strainer onto the lower retainer until
3. Remove the O-ring securing the fuel filter to the
the tabs click into the locked position.
housing. Remove the filter and discard it.
5. Install the fuel pump and fuel filter assembly as
4. Install a new filter into the housing and secure it
previously described.
with a new O-ring.
5. Attach the fuel filter housing onto the end cap and
Fuel Pump Replacement
push in on until the tabs click into the locked position.
6. Install the fuel pump and fuel filter assembly as
1. Remove the fuel pump and fuel filter assembly as
previously described.
previously described.
2. Use a flat blade screwdriver and break the fuel
pump locking tabs securing the fuel hose to the end
Fuel Regulator Replacement
cap.
3. Remove the fuel inlet strainer as previously de-
1. Remove the fuel pump and fuel filter assembly as
scribed.
previously described.
4. Disconnect the electrical connector from the fuel
2. Remove the wire terminal from the end of the reg-
pump.
ulator and filter housing.
5. Depress the locking tabs and separate the lower re-
3. Disengage the clip and remove it from the regula-
tainer from the upper retainer.
tor.
6. Remove the fuel pump from the upper retainer.
4. Withdraw the regulator and O-ring from the filter
7. If necessary, replace the isolators into the upper
housing. Discard the O-ring.
and lower retainers.
5. Install a new O-ring and regulator into the filter
8. Install a new fuel pump into the upper retainer.
housing. Push in until both parts are seated.
9. Install the lower retainer onto the upper retainer
6. Install the clip and push in on until the tabs click
and push in on until the tabs click into the locked posi-
into the locked position.
tion.
7. Install the fuel pump and fuel filter assembly as
10. Install the hose onto the end cap.
previously described.
11. Connect the electrical connector onto the fuel
pump.
Fuel Inlet Strainer Replacement
12. Install the fuel inlet strainer as previously de-
scribed.
14
1. Remove the fuel pump and fuel filter assembly as
13. Install the fuel pump and fuel filter assembly as
previously described.
previously described.
Table 10 FUEL SYSTEM TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N•m
Fuel cap trim ring screw
-
18-22
2.0-2.5
Fuel gauge bolts
15-20
-
20-27
Fuel tank console screw
-
18-24
2.0-2.7
Fuel tank mounting bolts
15-20
-
20-27
Fuel tank top plate screws
-
20
2.3
Induction module bolts (EFI)
upper and lower
-
97-142
11-16
546
SUPPLEMENT
CHAPTER EIGHT
ELECTRICAL SYSTEM
ALTERNATOR
wiring harness grommet to help ease it
out of the crankcase boss receptacle.
Refer to Figure 73.
7. Use an awl to carefully lift the capped lip on the
grommet (Figure 75) from the crankcase and push it
Rotor Removal/Installation
into the bore.
8. Carefully push the stator wires and grommet (B,
The removal and installation procedure is the same
Figure 74) through the crankcase bore and remove
as on all other models, except the washer previously
the stator assembly.
used inside and outside of the rotor has been
9. Inspect the stator mounting surface on the crank-
eliminated.
case for oil residue from a damaged oil seal. Clean it
off if necessary.
10. Inspect the stator wires (A, Figure 76, typical) for
Stator Removal
fraying or damage.
1. Remove the rotor as described in this Supplement
11. Inspect the rubber grommet (B, Figure 76) for
and Chapter Eight.
deterioration or hardness.
12. Check the stator connector pins for looseness or
NOTE
damage.
On models so equipped, always disarm
the optional TSSM security system
prior to disconnecting the battery or the
Stator Installation
siren will sound.
1. Apply a light coat of electrical contact cleaner or
2. Disconnect the negative battery cable as described
glass cleaner to the wiring harness grommet to help
in this Supplement.
ease it into the crankcase boss receptacle.
3. Pull back the rubber boot at the plug cover. Release
2. Insert the electrical harness and grommet into the
the locking tab and disconnect the alternator rotor
crankcase boss receptacle and carefully pull it through
electrical connector from the voltage regulator
until the grommet is correctly seated.
connector.
CAUTION
4. Insert a small screwdriver between the socket
New T27 Torx screws must be installed.
housing side of connector going to the alternator stator
The threadlocking compound origi-
and the locking wedge on the socket housing. Gently
nally applied to the Torx screws is for
pivot the screwdriver tip and pop the wedge loose.
one time use only. If a used Torx screw
5. Lift the terminal latches inside the socket housing
is installed, it can work loose and cause
and back the sockets through wire end of connector.
engine damage.
6. Remove the four T27 Torx screws (A, Figure 74)
3. Move the stator into position on the crankcase and
securing the stator assembly to the crankcase. New
install four new Torx screws (A, Figure 74). Tighten
Torx screws must be used on installation.
the screws to 55-75 in.-lb. (6.2-8.4 N•m).
NOTE
4. Move the wires to the right side of the motorcycle.
If necessary, spray electrical contact
5. Apply a light coat of dielectric compound to the
cleaner or glass cleaner around the
electrical connector prior to assembling it. Reassem-
2002-2005 MODEL SERVICE INFORMATION
547
73
CHARGING SYSTEM-ALL MODELS (2004-ON)
From main harness
1. Rotor
8. Connector
2. Stator coil assembly
9. Washer
3. Allen bolt
10. Screw
4. Voltage regulator
11. Nut
5. Bolt
12. Connector
6. Connector
13. Connector
7. Plug cover
14
74
75
548
SUPPLEMENT
ble the electrical connector socket by reversing Steps
76
4 and 5 of Removal. Make sure it has locked together
securely.
6. Connect the alternator rotor electrical connector
onto the voltage regulator connector. Make sure they
are push together until the tab clicks into the locked
position. Pull the rubber boot back into place.
7. Install the rotor as described in this Supplement.
VOLTAGE REGULATOR
Removal/Installation
NOTE
Refer to Figure 73.
On models so equipped, always disarm
the optional TSSM security system
NOTE
prior to disconnecting the battery or the
On models so equipped, always disarm
siren will sound.
the optional TSSM security system
prior to disconnecting the battery or the
1. Disconnect the negative battery cable as described
siren will sound.
in Chapter Eight.
1. Disconnect the negative battery cable as described
2. Remove the cover from the electrical panel as
in Chapter Eight.
described in this Supplement.
2. Pull back the rubber boot at the plug cover. Release
3. Disconnect the secondary lead from each spark
the locking tab and disconnect the voltage regulator
plug (Figure 78).
electrical connector from the alternator stator
4. Disconnect the front cylinder’s secondary lead
connector.
from the clip on the frame.
3. Release the locking tab and disconnect the voltage
5. Disconnect the electrical connector from the
regulator electrical connector from the main wiring
backside of the ignition coil.
harness.
4. Remove the two bolts securing the voltage regula-
6A. On FXDL, FXDLI, FXDWG, FXDWGI,
tor to the frame cross member.
FXDC and FXDCI models, unscrew the long screw
5. Remove the voltage regulator and related wiring
and washer securing the ignition coil cover and ig-
from the frame.
nition coil. Do not lose the spacer between the cover
and the ignition coil.
6. Install by reversing these removal steps. Note the
following:
6B. On FXD, FXDI, FXDX and FXDXI models,
a. Tighten the bolts to 60-80 in.-lb. (6.8-9.0 N•m).
unscrew the short screw securing the ignition coil.
b. Apply a light coat of dielectric compound to the
7. Remove the ignition coil from the electrical
electrical connectors prior to installing them.
panel.
c. Connect both voltage regulator electrical con-
8. Install by reversing these removal steps. Tighten
nectors. Make sure they are push together until
the screws to 50 in.-lb. (5.6 N•m).
the tab clicks into the locked position. Pull the
rubber boot back into place.
Ignition Control Module (2004-On
Carbureted Models) and Electronic
IGNITION SYSTEM
Control Module (2004-On Fuel
(2004-ON MODELS)
Injected Models) Removal/Installation
Ignition Coil Removal/Installation
Refer to the Electrical Panel section in this
Refer to Figure 77.
Supplment.
2002-2005 MODEL SERVICE INFORMATION
549
77
IGNITION SYSTEM COMPONENTS-ALL MODELS
(2004-ON)
1. Ignition coil (fuel injected models)
2. Screw (FXD, FXDI, FXDX, FXDXI)
3. Spacer (FXDL, FXDLI, FXDWG, FXDWGI)
4. Coil cover (fuel injected models)
5. Washer
6. Screw (FXDL, FXDLI, FXDWG, FXDWGI)
7. Ignition coil (carbureted models)
14
8. Coil cover (carbureted models)
9. Ignition module (carbureted models)
10. Ignition module (fuel injected models)
11. Spark plug cable-front cylinder
12. Spark plug cable-rear cylinder
13. Spark plugs
14. Screw
550
SUPPLEMENT
Crankshaft Position Sensor (CKP)
78
(2004-On Models)
The crankshaft position sensor (Figure 79) is lo-
cated on the front left side of the crankcase next to
the oil filter.
NOTE
On models so equipped, always disarm
the optional TSSM security system
prior to disconnecting the battery or the
siren will sound.
1. Disconnect the negative battery cable as described
3. Push in on the bulb (B, Figure 81), rotate it and re-
in Chapter Eight.
move it.
2. Remove the Allen screws, and captive washers,
4. Install a new bulb and lens.
and withdraw the CKP sensor (Figure 80) and
5. Push the lens cap into the housing until is snaps
O-ring from the crankcase.
into place.
3. Located above the voltage regulator and alterna-
tor stator electrical connector (Figure 73), push on
the CKP electrical connector and disengage it from
Taillight/Brake Light Replacement
the T-stud on the mounting plate.
(2003-On Models)
4. Separate the electrical connector and remove the
CKP and wiring harness from the frame.
Taillight/Brake light bulb replacement is the
5. Install by reversing these removal steps. Note
same as previous models with the following excep-
the following:
tion. On 2003 models, rotate the blown bulb and re-
a. Install a new O-ring and apply engine oil to it
move it from the socket assembly, then install a new
prior to installation.
bulb. On 2004-on models, pull the bulb straight out
b. Tighten the Allen screws to 90-120 in.-lb.
from the socket assembly, and install a new bulb.
(10.2-13.6 N•m).
The following are the bulb specifications:
1. Taillight bulb: 7 watts.
2. Brake light bulb: 2003 models (bayonet type) 27
STARTING SYSTEM
watts, 2004-on models (wedge type) 25 watts.
Starter Removal/Installation
(2004-On Models)
SWITCHES
The starter removal and installation is the same as
Ignition/Light Switch
on previous models with the exception of the torque
Removal/Installation
specification on the starter jackshaft bolt. Tighten
(2004-On FXDWG and FXDWGI Models)
the bolt to 60-80 in.-lb. (6.8-9.0 N•m).
1. Remove the fuel tank console for FXDWG and
FXDWGI models as described in the Chapter Seven
LIGHTING SYSTEM
section of this Supplement.
2. Note the location and color of the wire colors at-
Front Turn Signal Bulb Replacement
tached to the ignition switch. Disconnect the wires
(2003-On Models)
from the ignition switch.
1. Locate the notch in the lens cap.
3. Remove the screws securing the ignition switch to
2. Insert a coin into the notch and carefully twist the
the underside of the console and remove the switch.
coin until the lens cap come off the housing (A, Fig-
4. Install by reversing these removal steps. Tighten
ure 81).
the mounting screws securely.
2002-2005 MODEL SERVICE INFORMATION
551
79
ENGINE SENSORS
1. Screw
2. Clamp
3. MAP sensor
4. Seal
5. Engine temperature
sensor
6. Screw-self tapping
7. Plate
8. Oil pressure switch
9. Wiring harness
10. O-ring
11. CKP sensor
12. Bolt
14
80
81
552
SUPPLEMENT
82
ELECTRICAL PANEL (2004-ON)
1. Screw
8. Cover
2. Washer
9. Main fuse (40A)
3. Siren
10. Washer
4. Electrical panel
11. Bolt
5. Grommet
12. Turn signal module (TSM)
6. Mounting pin
or turn signal module
7. Nut
(TSSM)
ELECTRICAL PANEL
(2004-ON MODELS)
83
The electrical panel assembly mounts on the left
side of the motorcycle. The panel assembly houses the
fuses, ignition control module (carbureted models)
or electronic control module (fuel injected models),
starter relay (carbureted models), system relay (fuel
injected models), turn signal canceller, turn sig-
nal/security module and siren.
Refer to Figure 82.
prior to disconnecting the battery or the
siren will sound.
Removal/Installation
1. Remove the seat as described in Chapter Thirteen.
NOTE
On models so equipped, always disarm
2. Disconnect the negative battery cable as described
the optional TSSM security system
in Chapter Eight.
2002-2005 MODEL SERVICE INFORMATION
553
84
3. Hold onto both sides of the cover, pull straight out
module (ECM [2004-on fuel injected models]), per-
and remove the cover (Figure 83) from the electrical
form the following:
panel.
a. Carefully disconnect the
12-pin
(ICM) or
4. Remove the 40 amp main fuse from the connector.
36-pin (ECM) electrical connector (B, Figure
5. Disconnect the main fuse connector as follows:
85) from the module.
a. Insert a small flat blade screwdriver into the
b. Disconnect the ignition coil four-pin electrical
slots on each side of the main fuse holder.
connector from the backside of the ignition coil
b. Carefully depress the tabs on the main fuse
14
unit.
holder connector and disengage it from the
c. Disconnect the spark plug secondary wires
electrical panel.
from the ignition coil unit.
6. To remove the TSM/TSSM unit, perform the fol-
lowing:
d. Remove the front long screws and washers se-
a. Depress the tab (A, Figure 84) on the electrical
curing the electrical panel to the frame mount.
panel securing the TSM/TSSM unit (B).
e. Remove the top short screws and washers se-
b. Pull the TSM/TSSM unit from the opening in
curing the frame mount.
the panel, disconnect the electrical connector
f. Carefully push the electrical connectors back
from unit, and remove it.
through the opening in the electrical panel.
7. Slide the data link connector (A, Figure 85) to-
ward the front and disengage it from the electrical
NOTE
panel.
On fuel injected models, note the loca-
8. To remove the ignition control module (ICM
tion of the ground strap on the front
[2004-on carbureted models]) or electronic control
mounting screw.
554
SUPPLEMENT
85
g. Remove the screws securing the ICM or ECM
TURN SIGNAL MODULE (TSM) AND
unit to the base of the electrical panel and re-
TURN SIGNAL MODULE/SECURITY
move the unit.
MODULE (TSSM)
(2004-ON MODELS)
9. Remove the electrical panel from the frame.
10. Install by reversing these removal steps. Note the
The turn signal module and turn signal module/se-
following:
curity module operation is the same as on prior years
with the exception of the removal and installation of
a. Tighten the top short screws to 100 in.-lb. (11.3
the unit.
N•m).
Removal and installation are covered under Electri-
b. Tighten the front long screws to 50 in.-lb. (5.6
cal Panel in this section.
N•m).
c. Apply a light coat of dielectric compound to the
STARTER RELAY REPLACEMENT
electrical connectors prior to installing them.
(2004-ON MODELS)
d. Connect the electrical connectors. On connec-
tors so equipped, make sure they are push to-
NOTE
gether until the tab clicks into the locked
On models so equipped, always disarm
position.
the optional TSSM security system
2002-2005 MODEL SERVICE INFORMATION
555
86
FUSE PANEL (CARBURETED MODELS)
1. Main 40A fuse
2. Spare fuse
3. Spare fuse
4. Battery 15A fuse
5. Accessory 15A fuse
6. Instrument 15A fuse
7. Ignition 15A fuse
8. Lights 15A fuse
9. Starter 15A relay
prior to disconnecting the battery or the
SYSTEM RELAY REPLACEMENT
siren will sound.
(2004-ON FUEL INJECTED MODELS)
14
NOTE
1. Remove the seat as described in Chapter Thirteen.
On models so equipped, always disarm
the optional TSSM security system
2. Disconnect the negative battery cable as described
prior to disconnecting the battery or the
in Chapter Eight.
siren will sound.
3. Hold onto both sides of the cover, pull straight out
1. Remove the seat as described in Chapter Thirteen.
and remove the cover (Figure 83) from the electrical
2. Disconnect the negative battery cable as described
panel.
in Chapter Eight.
4. Pull straight out and remove the starter relay from
3. Hold onto both sides of the cover, pull straight out
the electrical panel. Refer to Figure 86 or Figure 87.
and remove the cover (Figure 83) from the electrical
panel.
5. Install the starter relay onto the electrical panel.
4. Pull straight out and remove the system relay from
6. Install the cover onto the electrical panel.
the electrical panel. Refer to Figure 87.
556
SUPPLEMENT
87
FUSE PANEL (FUEL INJECTED MODELS)
1. Main 40A fuse
2. ECM 15A fuse
3. Fuel pump 15A fuse
4. Spare fuse
5. Spare fuse
6. Battery 15A fuse
7. Accessory 15A fuse
8. Instrument 15A fuse
9. Ignition 15A fuse
10. Lights 15A fuse
11. Starter relay
12. System relay
5. Install the starter relay onto the electrical panel.
1. Remove the fuel tank console as described in the
6. Install the cover onto the electrical panel.
Chapter Seven section of this chapter.
2. Unscrew and remove the reset switch rubber boot.
3. Remove the reset switch from the console.
INSTRUMENTS
4. Remove the screws securing the back clamp to the
Removal/Installation
console.
(2005 FXDC, FXDCI Models)
5. Remove the back clamp and remove the speedom-
eter and/or tachometer from the console.
Removal and installation is the same as on prior
6. Remove the gasket from the meter or console.
FXD Series models with the exception of the shape of
7. Install by reversing these removal steps. Note the
the shape of the meter housing as shown in Figure 88.
following:
a. If necessary, apply alcohol or glass cleaner to
the gasket to ease its installation onto the meter.
Removal/Installation
b. Tighten the back clamp screws securely. Do not
(2004-On FXDL, FXDLI Models)
pinch the wiring between the back clamp and
Refer to Figure 89.
the console.
2002-2005 MODEL SERVICE INFORMATION
557
88
INSTRUMENTS-FXDC, FXDCI (2005)
1. Reset switch
10. Back plate
2. Reset switch rubber boot
11. Screw
3. Speedometer
12. Connector (12-pin)
4. Connector
13. Indicator lamp bezel
5. Front gasket
14. Indicator lamp lens
6. Bolt
15. Indicator lamp housing
7. Washer
16. Screw
8. Handlebar holder/speedometer
17. Lamps
mounting bracket
18. Wiring harness/bulb sockets
9. Rear gasket
14
Removal/Installation
a. If necessary, apply alcohol or glass cleaner to
(2004-On FXDWG, FXDWGI Models)
the gasket to ease its installation onto the meter.
b. Tighten the back clamp screws securely. Do not
Refer to Figure 90.
pinch the wiring between the back clamp and
1. Remove the fuel tank console as described in the
the console.
Chapter Seven section of this Supplement.
2. Unscrew and remove the reset switch rubber boot.
3. Remove the reset switch from the console.
FUSES AND MAXI-FUSE
4. Use a flat blade screwdriver and carefully pry be-
(2004-ON MODELS)
tween the three tabs on the back clamp and release it
from the speedometer. Remove the back clamp.
All models are equipped with a series fused to pro-
5. Remove the speedometer and gasket from the con-
tect the electrical system. The number of fuses varies
sole.
depending on model. The 40 amp circuit breaker used
6. Install by reversing these removal steps. Note the
on prior models has been replaced with the 40 amp
following:
maxi-fuse. Always carry spare fuses
558
SUPPLEMENT
89
FUEL TANK CONSOLE
(FXDL, FXDLI)
1. Tachometer
9. Reset switch rubber boot
2. Socket
10. Console
3. Gasket
11. Wiring harness
4. Screw
12. Clamp
5. Speed nut
13. Connector (12-pin)
6. Speedometer
14. Warning light
7. Socket
15. Back clamp
8. Gasket
16. Screw
2002-2005 MODEL SERVICE INFORMATION
559
90
FUEL TANK CONSOLE
(FXDWG, FXDWGI)
14
1. Speedometer
10. Ignition switch
2. Gasket
11. Screw
3. Bezel
12. Back clamp
4. Indicator lamp bezel
13. Indicator lamp assembly
5. Screw
14. Connector
6. Console
15. Trim gasket
7. Leather trim panel
16. Reset switch
8. Speed nut
17. Reset switch rubber
9. Push nut
boot
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