Harley Davidson 2005 touring models. Service repair manual — page 17

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● The increase in idle speed is intended to alert the rider

that the engine is warmed up to normal operating tem-

perature and the enrichener knob should be pushed all

Full-In

(Normal Running Position)

the way in.

1/2-Way

● Continuing to use the enrichener when the engine is at

Position

full operating temperature WILL CAUSE FOULED

Full-Out

SPARK PLUGS.

(Cold Engine Starts)

CAUTION

Pay close attention to the vehicle's warm-up time. Either

excessive or insufficient use of the enrichener may

f1808x4x

cause poor performance, erratic idle, poor fuel economy

and spark plug fouling.

Figure 4-2. Set the Enrichener Knob

NOTE

The following starting and operating instructions for all carbu-

Push the enrichener knob in to the 1/2 way position. Ride

reted motorcycles should be viewed as recommendations

an additional 1 minute or 1/2 mile (0.8 km).

only. They may be modified for individual vehicles.

Push the enrichener knob fully in.

Cool Engine

Warm Climate Or Hot Engine

Outside Temperature Cooler than 60˚ F

Turn the fuel valve to the ON position. Turn the Ignition/Light

Turn the fuel valve to the ON position. BE SURE THAT THE

Key Switch knob to the IGNITION position. Turn the Engine

THROTTLE IS CLOSED. Pull the enrichener knob to the “full

Stop Switch to the RUN position. Open throttle 1/8 - 1/4 turn.

out” position. Turn the Ignition/Light Key Switch knob to the

Press the Engine Start Switch to operate the electric starter.

IGNITION position. Turn the Engine Stop Switch to the RUN

DO NOT USE ENRICHENER.

position. Press the Engine Start Switch to operate the electric

starter.

NOTE

1. After initial 15-30 second warm-up, ride for 3 minutes or

If the engine does not start after a few turns or if one cylinder

2 miles (3.2 km) with enrichener knob in full out position.

fires weakly but engine does not start, it is usually because of

See Figure 4-2.

an over-rich (flooded) condition. This is especially true of a

hot engine. If the engine is flooded, push enrichener knob in

2. Push the enrichener knob in to the 1/2 way position. Ride

all the way, turn ignition on and operate starter with throttle

an additional 2 minutes or 2 miles (3.2 km).

wide open. DO NOT "pump" the throttle while turning over the

engine.

3. Push the enrichener knob fully in.

NOTE

If outside temperature is cooler than 20˚ F it may be neces-

ADJUSTMENTS

sary to pump the throttle control grip 2 or 3 times.

Outside Temperature Warmer than 60˚ F

Slow Idle

Turn the fuel valve to the ON position. BE SURE THAT THE

NOTE

THROTTLE IS CLOSED. Pull the enrichener knob to the “full

out” position. Turn the Ignition/Light Key Switch knob to the

Make certain enrichener knob is pushed all the way in before

IGNITION position. Turn the Engine Stop Switch to the RUN

adjusting engine idle. The CV carburetor enrichener-circuit

position. Press the Engine Start Switch to operate the electric

will cause the engine idle speed to increase to between 1500

starter.

and 2000 rpm with the enrichener knob pulled out fully and

the engine at normal operating temperature.

(With the

1. After the initial 15-30 second warm-up, ride for 1 minute

enrichener knob pulled out partially and normal engine oper-

or 1/2 mile (0.8 km) with enrichener knob in full out posi-

ating temperature, the engine idle speed will increase above

tion. See Figure 4-2.

normal idle speed (950-1050 rpm) to approximately 2000 rpm

4-6

2005 Touring: Fuel

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maximum with the enrichener knob pulled out fully). The

Enrichener Control

increase in idle speed is intended to alert the rider that the

engine is warmed-up and the enrichener knob should be

The fuel enrichener knob should open, remain open and then

pushed all the way in. Continued use of the enrichener, after

close without binding. The knurled plastic nut next to the

engine is at normal operating temperature, may cause fouled

enrichener knob controls the ease at which the cable slides

spark plugs.

within the conduit. If adjustment is needed, see Section 1.12

ENRICHENER CONTROL.

With the engine at normal operating temperature and the

enrichener all the way in (enrichener valve closed) adjust the

throttle stop screw so the engine idles at 1000 rpm.

NOTE

Use a test tachometer, connected to negative ignition coil ter-

minal to measure engine rpm on models without tachome-

ters.

2005 Touring: Fuel

4-7

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Top

14.

Float

Screw (3)

15.

O-ring

Spring

16.

Screw (4)

Vacuum piston

17.

Cable seal boot

Spring seat

18.

Cable guide

Jet needle

19.

Starter cap

Vacuum hose

20.

Enrichener valve

Needle jet

21.

Spring

Needle jet holder

22.

Throttle cable bracket

10.

Main jet

23.

Bracket screw

11.

Slow jet

24.

Bracket screw and washer

12.

4-sided Fuel valve with clip

25.

Idle speed adjust screw

13.

Pin

26.

Spring

27.

Collar

28.

Seal ring

29.

Manifold

30.

Flange

31.

Intake manifold seal (2)

32.

Lever

33.

Float bowl

34.

E-clip

avid

H arle

35.

Accelerator pump nozzle

36.

Spring

37.

Pump housing

38.

Spring

39.

Diaphragm

40.

O-Ring (2)

41.

Washer (3)

42.

Screw (3)

43.

Boot

44.

Rod

45.

Collar

46.

Screw (4)

47.

Rod

48.

Cotter pin (2)

NOTE

49.

Washer

With the exception of the jet sizes, all

50.

Washer

51.

Washer

FL models are equipped with the

52.

Washer

same basic carburetor.

53.

Washer

f2320x4x

Figure 4-3. Carburetor

4-8

2005 Touring: Fuel

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CARBURETOR

4.4

REMOVAL

Float Bowl

1WARNING

Vent

Gasoline is extremely flammable and highly explosive.

When servicing the fuel system, do not smoke or allow

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2. Remove air cleaner assembly. See Section 4.5 AIR

CLEANER, REMOVAL.

Locate the fuel enrichener knob under the left side of the

fuel tank, and loosen hex nut at backside of mounting

8982

bracket. Slide cable assembly free of slot in mounting

bracket.

Figure 4-4. Drain Carburetor Float Bowl

Rotate handle on fuel valve to the horizontal position to

shut the gasoline supply to the carburetor OFF.

1WARNING

Using a needle nose pliers, carefully pull idle cable bar-

rel from upper inboard hole in throttle wheel. Pull throttle

Some gasoline will drain from the fuel inlet hose when

cable barrel from remaining hole. Release idle and throt-

disconnected from the carburetor. Thoroughly wipe up

tle cables from guides in throttle cable bracket.

any spilled fuel immediately. Dispose of rags in a suit-

able manner. Gasoline is extremely flammable and

Pull vacuum hose elbow from fitting on inboard side of

highly explosive. Inadequate safety precautions could

carburetor.

result in death or serious injury.

10.

Carefully remove carburetor while drawing enrichener

5. Using a side cutters, cut clamp and remove fuel inlet

cable to right side of motorcycle.

hose from fitting at side of carburetor.

11.

Keeping carburetor upright, move assembly to bench

NOTE

area. Tilting carburetor, carefully pour gasoline in float

On California models, pull purge tube from fitting on same

bowl into a suitable container. Gasoline will exit float

side of carburetor.

bowl vent shown in Figure 4-4.

6. Gently work carburetor free of seal ring on intake mani-

fold.

INSTALLATION

1WARNING

As the carburetor is removed, be sure to keep assembly

1. Place carburetor into approximate position on right side

upright as the float bowl contains gasoline. Tilting the

of motorcycle while feeding enrichener cable over to left

carburetor or turning it upside down will cause the gaso-

side.

line to drain onto surrounding area. Gasoline is

2. Push vacuum hose elbow onto fitting on inboard side of

extremely flammable and highly explosive. Inadequate

carburetor.

safety precautions could result in death or serious

injury.

3. Install sleeve on throttle cable housing into shorter cable

guide in throttle cable bracket. Drawing throttle cable

7. If cruise control equipped, remove E-clip from groove at

downward, fit barrel end into lower outboard hole in

end of cruise cable housing. Remove cruise cable hous-

throttle wheel. Install sleeve and spring on idle cable

ing from cable guide in throttle cable bracket. Push plas-

housing into longer cable guide inserting barrel end into

tic end fitting on cruise cable to outboard side to release

upper inboard hole in throttle wheel.

from wheel pin.

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10. Install air cleaner assembly. See Section

4.5 AIR

8981

CLEANER, INSTALLATION.

11. Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

12. Rotate handle of fuel valve clockwise to the vertical posi-

tion and carefully inspect for leaks. Return the valve to

the OFF position when finished.

13. Adust the engine idle speed. See Section

4.3

ENRICHENER (CARBURETED), ADJUSTMENTS.

DISASSEMBLY

Vacuum Piston Chamber

Placing a 14mm open end wrench on hex, loosen plastic

Figure 4-5. Remove Enrichener Cable

fitting at enrichener bore of carburetor housing. See Fig-

ure 4-5. Rotate enrichener cable in a counterclockwise

direction to unthread fitting and remove valve assembly.

Verify that cables are fully seated in channel of throttle

2. Remove gold Phillips screw (with lockwasher) at side of

wheel, and using cable adjusters at handlebar, tighten

carburetor to release throttle cable bracket. Remove gold

cables as necessary to keep barrel ends from dislodging.

Phillips screw

(with top collar) to free throttle cable

Verify operation by turning throttle grip and observing

bracket from carburetor top. Set bracket aside.

cable action.

3. Remove three remaining top screws to release carbure-

If cruise control equipped, slide plastic end fitting over

tor top from body.

cap of wheel pin. Push on end fitting until it snaps in

place. Slip cruise cable housing into cable guide in throt-

Remove vacuum piston spring. Carefully raise dia-

tle cable bracket. Install new E-clip into groove at end of

phragm to remove vacuum piston assembly. Remove

cruise cable housing.

spring seat and jet needle from vacuum piston bore. See

Figure 4-6.

NOTE

The fit between the carburetor and seal ring is tight. Prior to

assembly, lubricate mating surfaces with liquid dishwashing

Float Chamber

soap or tire mounting lube. Always install new seal ring if

dried out, cracked or otherwise damaged.

Turn carburetor upside down and remove four Phillips

6. Lubricate inside diameter of seal ring. Also apply a light

screws at bottom to remove float bowl from carburetor

film of lubricant to carburetor housing where casting

body.

comes into contact with seal ring. Gently work carburetor

into seal ring.

7. Slide new clamp onto free end of fuel inlet hose. Install

hose onto brass fitting at side of carburetor. Making sure

7754

clamp is positioned inboard of lip on fitting, crimp clamp

Vacuum

Piston

using HOSE CLAMP PLIERS (HD-97087-65B).

NOTE

Spring

On California models, push purge tube onto fitting on same

side of carburetor.

Moving to left side of motorcycle, slide threaded portion

of enrichener cable into slot of mounting bracket. Flat on

threads must face rear of motorcycle for script on

enrichener knob to be right side up. With the external

tooth lockwasher and hex nut positioned on the inboard

side of the mounting bracket, tighten hex nut to 20-35 in-

Jet

Spring

lbs (2.3-4.0 Nm).

Needle

Seat

Adjust throttle cables. See Section

2.21 THROTTLE

CABLES (NON-CRUISE), ADJUSTMENT.

Figure 4-6. Vacuum Piston Chamber Components

4-10

2005 Touring: Fuel

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NOTE

Since accelerator pump rod is now loose, remove from hole

7751

Float

in lever at side of carburetor body.

CAUTION

Tapping the float pin out from the squared pedestal side

will result in damage that requires carburetor replace-

ment

Wireform

Using a small center punch and hammer, carefully tap

Clip

float pin from holes in pedestals. The rounded pedestal

has an interference fit to ensure that the float pin is

securely held, so always tap out the pin in the direction

Float Pin

Fuel Valve

of the cast-in arrow (that is, from the interference side).

See Figure 4-7.

Remove float and fuel valve. Carefully slide clip on fuel

7750

Needle Jet Holder

valve from tab on float. Remove wireform clip from

groove in fuel valve. See A of Figure 4-8.

Using slot at top, turn main jet with flat tip screwdriver to

unthread from needle jet holder. If necessary, hold hex

on needle jet holder with a 5/16 inch wrench to prevent

rotation. See Figure 4-10.

Main Jet

Using a 5/16 inch wrench, turn hex on needle jet holder

Needle Jet

to unthread from main jet bore.

Turn carburetor right side up to drop out needle jet,

7755

which is loose in main jet bore. See B of Figure 4-8.

Insert thin bladed flat tip screwdriver into slow jet bore.

See Figure 4-10. Using slot at top of slow jet, unthread

to remove. See C of Figure 4-8.

Slow Jet

Disassemble accelerator pump from float bowl. See Fig-

ure 4-9. Proceed as follows:

Figure 4-8. Float Chamber Components

Rubber

f1868x4x

Boot

Rounded

Rod

Pedestal

Spring

Float Pin

Diaphragm

O-Rings

Figure 4-9. Accelerator Pump Components

Arrow

a. Remove rubber boot from post at top of accelerator

pump upper housing.

b. Turn float bowl upside down. Alternately loosen and

a0183x4x

then remove three Phillips screws

(with lock-

washers) to release accelerator pump lower hous-

Figure 4-7.

Remove Float Pin in Direction of Arrow

ing.

2005 Touring: Fuel

4-11

HOME

c. Remove spring and diaphragm from accelerator

Main Circuit

pump upper housing. Remove two O-rings from

a. Plugging main jet hole in carburetor throat, spray

lower housing.

carburetor cleaner into air inlet hole of main circuit.

See A of Figure 4-11. While spraying, verify that

solution exits main jet bore at bottom of carburetor

CLEANING AND INSPECTION

housing. See B of Figure 4-11.

b. Using a tapered, rubber-tipped nozzle on the air

Carburetor Housing

hose (to prevent both loss of air pressure and to

avoid scratching or nicking the bore), apply low pres-

1. Clean all internal air/fuel passages in carburetor housing

sure compressed air into air inlet hole to blow carbu-

with carburetor cleaner. Blow out passages using low

retor cleaner out of hole in carburetor throat. Placing

pressure compressed air. Proceed as follows:

gloved finger over hole in carburetor throat, blow

carburetor cleaner out of main jet bore at bottom of

carburetor housing.

1WARNING

Compressed air can pierce the skin and cause injury.

Float Bowl Vent

Never use your hand to check for leaks or to determine

a. Spray carburetor cleaner into air inlet hole of float

air flow rates. Wear safety glasses to shield your eyes

bowl vent. See A of Figure 4-11. While spraying, ver-

from flying dirt and debris. Failure to comply could result

ify that solution exits two holes in float bowl chamber

in death or serious injury.

at bottom of carburetor housing. See B of Figure 4-

11.

Slow Speed Circuit

b. Using a tapered, rubber-tipped nozzle on the air

Spray carburetor cleaner into air inlet hole of slow

hose (to prevent both loss of air pressure and to

speed circuit. See A of Figure 4-11. While spraying,

avoid scratching or nicking the bore), apply low pres-

verify that solution exits slow jet bore at bottom of

sure compressed air into air inlet hole of float bowl

vent to blow carburetor cleaner out of holes in float

carburetor housing. See B of Figure 4-11. Placing

gloved finger over slow jet bore, verify that solution

bowl chamber.

exits four pin holes just inboard of the throttle plate,

as well as the single pin hole outboard of the throttle

Vacuum Piston Chamber Components

plate.

Thorougly clean all loose parts (except diaphragm) with

Using a tapered, rubber-tipped nozzle on the air

carburetor cleaner. See Figure 4-6. Blow dry using low

hose (to prevent both loss of air pressure and to

pressure compressed air.

avoid scratching or nicking the bore), apply low pres-

sure compressed air into air inlet hole to blow carbu-

retor cleaner out of slow jet bore. Placing gloved

1WARNING

finger over slow jet bore, blow carburetor cleaner out

Compressed air can pierce the skin and cause injury.

of pin holes inboard and outboard of throttle plate.

Never use your hand to check for leaks or to determine

air flow rates. Wear safety glasses to shield your eyes

from flying dirt and debris. Failure to comply could result

8979

in death or serious injury.

Slow Jet

2. Inspect parts as follows:

a. Hold vacuum piston up to strong light source. Exam-

ine diaphragm for pin holes, cuts, tears or pinching.

Replace if any damage is found.

b. Examine passage at bottom of vacuum piston bore.

Verify that passage is clean and open.

c. Examine vacuum piston spring for stretching, kink-

ing, distortion or other damage. Inspect spring seat

for cracks. Replace parts if necessary.

Main Jet

d. Examine slides at sides of vacuum piston to verify

that surfaces are clean and smooth. Clean or buff

Fuel Valve

out any rough surfaces.

Bore

e. Examine tip of jet needle for grooves or scratches.

Needle should be completely straight, while surface

condition at taper should be smooth and even.

Figure 4-10. Carburetor Housing

Replace needle if necessary.

4-12

2005 Touring: Fuel

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b. Inspect float pin for damage or distortion. Replace

float pin if corroded, nicked or bent.

8980

c. Clean float and inspect for cracks or other damage.

Float Bowl

Submerge float in a glass of water. Replace float if

Vent

not water tight.

Air Inlet

d. Depress pin on fuel valve to verify that it returns to

the full-out position. Thoroughly clean valve with

carburetor cleaner if pin is dirty or sticks. Inspect

rubber cone on valve for dirt, cracks, hardening or

wear. Inspect wireform clip for distortion. Replace

fuel valve assembly if any of these conditions are

found.

e. Inspect fuel valve seat in carburetor housing for dirt,

damage or corrosion. Replace carburetor if seat

damage or corrosion is present.

Slow Speed

Main Circuit

Circuit

Verify cleanliness of main jet, needle jet holder and

Air Inlet

needle jet. Verify that orifices in needle jet holder

are clean and open. Replace parts if damaged.

g. Verify cleanliness of slow jet. Be sure that all orifices

Vent

8978

are clean and open. Replace jet if damaged.

Holes

Accelerator Pump

h. Inspect the accelerator pump diaphragm for holes,

cuts, tears or cracks. Replace diaphragm if

deformed or damaged.

Examine spring for stretching, kinking or distortion.

Replace if any damage is found.

Inspect the accelerator pump rod for straightness.

Replace the rod if bent.

Main Jet

k. Inspect rubber boot and two O-rings for cuts, tears

Bore

or signs of deterioration. Replace if necessary.

Slow Jet

Bore

ASSEMBLY

Figure 4-11. Clean Air/Fuel Passages

Vacuum Piston Chamber

Float Chamber Components

Install vacuum piston into carburetor body. Slides on pis-

1. Thorougly clean all loose parts with carburetor cleaner.

ton are offset, so piston will fit into slide track groove only

one way. If vacuum piston does not fit, rotate assembly

See Figure 4-8. Blow dry using low pressure com-

pressed air.

180°.

2. Insert jet needle into vacuum piston bore, so that it

enters center hole at bottom. In the installed position,

1WARNING

head of needle contacts boss at bottom of vacuum pis-

ton bore, while length of shaft resides in main jet bore.

Compressed air can pierce the skin and cause injury.

Never use your hand to check for leaks or to determine

3. With the legged side down, slide spring seat over top of

air flow rates. Wear safety glasses to shield your eyes

needle in vacuum piston bore. Slide spring over spring

from flying dirt and debris. Failure to comply could result

seat.

in death or serious injury.

4. Verify that lip on edge of diaphragm is seated in groove

of carburetor flange.

Inspect parts as follows:

NOTE

a. Inspect O-ring in groove of float bowl for cuts, tears

Diaphragm expands when in contact with fuel. If diaphragm

or signs of deterioration. Replace O-ring if distorted

is difficult to seat in groove because of this condition, allow

or if sealing surface is damaged.

diaphragm to dry before attempting to install.

2005 Touring: Fuel

4-13

HOME

Fit free end of spring over boss on inboard side of carbu-

retor top, and keeping spring straight, align holes in top

Start Float Position

a0186x4x

with those in flange.

Holding top to flange, check for proper diaphragm seal

by pushing up on vacuum piston (from intake side) and

releasing. If diaphragm is sealed correctly, very slight

resistance should be felt when pushing up, and piston

should be slow to extend. If piston movement is

restricted, spring is cocked. Lift up on top and then lower

carefully keeping spring coils straight.

Float

Install three black top screws in holes furthest from throt-

tle wheel. Alternately tighten screws until snug.

Intake Manifold Side Down

Slide gold top collar into remaining hole in carburetor top.

With end of idle screw resting against idle cam stop,

Correct Float Position

align holes in throttle cable bracket with those in carbure-

tor body and top cover. To prevent bending bracket or

cam stop, first install gold Phillips screw

(with lock-

washer) at side of carburetor. At carburetor top, install

remaining Phillips screw.

Carefully insert enrichener valve into carburetor bore.

Float

Start threaded end of plastic fitting into bore, and then

rotate cable in a clockwise direction to install. Exercising

0.413- 0.453 in.

caution to avoid damaging the plastic construction,

(10.49-11.51 mm)

tighten fitting using a 14mm open end wrench. See Fig-

ure 4-5.

15˚ to 20˚

Pin Return Spring

Collapsed

Float Chamber

C Incorrect Float Position

Place needle jet into main jet bore. See Figure 4-10. Be

sure end with chamfered edge and larger ID goes in first.

Insert needle jet holder into main jet bore, and using a 5/

16 inch wrench, turn hex until snug.

Float

Thread main jet into needle jet holder. Using slot at top of

main jet, tighten with flat tip screwdriver until snug.

Insert slow jet into slow jet bore. See Figure 4-10. Insert

thin bladed flat tip screwdriver into bore, and using slot at

top of slow jet, tighten until snug.

Greater Than 20˚

Install wireform clip into groove on pin side of fuel valve,

if removed. Using wireform clip, carefully hang fuel valve

onto tab of float, so that tip of rubber cone hangs flush

Figure 4-12. Float Check and Adjustment

with top of float (the top being the side opposite the pivot

arm).

Place float into cavity of carburetor inserting fuel valve

Insert float pin through squared pedestal and pivot arm

of float into rounded pedestal. Since the rounded pedes-

into bore between pedestals. See Figure 4-10.

tal has an interference fit to ensure that the float pin is

securely held, always install pin from the loose side (in

CAUTION

the direction opposite the cast-in arrow). Using a small

center punch and hammer, carefully tap float pin until

Tapping the float pin in from the rounded pedestal side

ends are flush with outboard sides of pedestals.

will result in damage that requires carburetor replace-

ment.

Perform float level check as follows:

4-14

2005 Touring: Fuel

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a. Place carburetor on a clean flat surface with the

Install float and check float level again. Repeat pro-

intake manifold side down. See A of Figure 4-12.

cedure as necessary until float level is within specifi-

cation.

b. Tilt the carburetor 15° to 20° in a counter-clockwise

direction until float comes to rest. See B of Figure 4-

Install new O-ring into groove of float bowl, if removed.

12.

Be sure to thoroughly clean groove before O-ring instal-

lation.

NOTE

The measurements will be incorrect if the carburetor is tilted

10.

Assemble accelerator pump as follows:

less than 15 ° or more than 20 °.

a. With the flat side toward the casting, install two O-

c. Using a dial vernier caliper or dial caliper depth

rings into counterbores of accelerator pump lower

gauge, measure the distance from the face of the

housing.

carburetor flange to the outboard edge of the float.

Be careful not to push on float while measuring.

b. Install diaphragm into accelerator pump upper

housing. Verify that lip on edge of diaphragm is fully

d. If the measurement is between

0.413 inch and

seated in groove.

0.453 inch (10.49 -11.51 mm), then the float level is

within specification. Proceed to step 9.

c. Place spring onto spring seat at center of installed

e. If the float level is not within specification, remove

diaphragm.

the float, and referencing the table below, carefully

d. Keeping spring straight, mate upper and lower

bend the tab slightly to adjust the float level. For

housings of accelerator pump. Install three Phillips

example, to increase the float measurement, bend

screws (with lockwashers).

the tab toward the carburetor body. This will have

the affect of decreasing the amount of gas in the

e. Install rubber boot onto post at top of accelerator

float bowl after assembly.

pump upper housing.

Hook accelerator pump rod into hole on inboard

Table 4-1. Float Level Tab

side of lever at side of carburetor body.

Float

Amount of Gas

Bend Tab

11.

Install float bowl at bottom of carburetor body engaging

Measurement

in Float Bowl

free end of accelerator pump rod in hole of rubber boot.

Toward

To Increase

Decreased

12.

Install four Phillips screws to secure float bowl at bottom

Carburetor Body

of carburetor body. Tighten screws until snug.

Away From

To Decrease

Increased

Carburetor Body

2005 Touring: Fuel

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HOME

AIR CLEANER

4.5

REMOVAL

CLEANING AND INSPECTION

1. Thoroughly clean air cleaner cover, breather tubes and

Remove large allen head socket screw in center of air

backplate with warm, soapy water.

cleaner cover. Remove air cleaner cover with rubber

2. Clean the filter element as follows:

seal. See Figure 4-13.

Remove three T27 TORX screws to release cover

1WARNING

bracket from filter element.

Do not use gasoline or solvents to clean the filter ele-

Remove filter element pulling two breather tubes from

ment. Volatile or flammable cleaning agents may cause

holes on inboard side.

an intake system fire, which could result in death or seri-

ous injury.

Remove gasket from sleeve on inboard side of filter ele-

ment. Discard gasket.

a. Wash the filter element in warm, soapy water. To

remove soot and carbon, soak element for 30 min-

Remove breather tubes from fittings on two cylinder

utes in warm water with mild detergent.

head breather bolts.

1WARNING

Remove two cylinder head breather bolts from backplate

using a 7/16 inch deepwell socket.

Compressed air can pierce the skin and cause injury.

Never use your hand to check for leaks or to determine

Remove backplate from cylinder heads. On carbureted

air flow rates. Wear safety glasses to shield your eyes

California models, pull clean air inlet tube (to charcoal

from flying dirt and debris. Failure to comply could result

canister) from hole on inboard side of backplate.

in death or serious injury.

Remove two O-rings from grooves around breather bolt

b. Dry the filter element using low pressure com-

holes on inboard side of backplate. Discard O-rings.

pressed air (32 psi/221 kPa maximum). Rotate the

element while moving air nozzle up and down the

Remove gasket from inboard side of backplate. Discard

element interior. Do not rap the element on a hard

gasket.

surface.

f1624x4x

Cover Screw

4. T27 Torx Screw (3)

7. Gasket

10. Backplate

Air Cleaner Cover

5. Cover Bracket

8. Breather Tube (2)

11. O-Ring (2)

Rubber Seal

6. Filter Element

9. Breather Bolt (2)

12. Gasket

Figure 4-13. Air Cleaner Assembly

4-16

2005 Touring: Fuel

HOME

c. Hold the filter element up to a strong light source.

NOTE

The element can be considered sufficiently clean if

light is uniformly visible through the media.

Air cleaner mounting without installation of the breather

tubes allows crankcase vapors to be vented into the atmo-

NOTE

sphere in violation of legal emissions standards.

Replace the filter element if damaged or if filter media cannot

be adequately cleaned.

Place filter element onto backplate with the flat side

down, so that hole on inboard side of element fits over

3. Inspect the breather tubes and rubber seal for cuts,

molded boss in backplate.

tears, holes or signs of deterioration. Replace as neces-

sary. Direct compressed air through the breather tubes

Align holes in cover bracket with those in filter element

to be sure that they are not plugged.

and start three screws. Stamp on cover bracket points to

downside. Using a T27 TORX drive head, alternately

tighten screws to 20-40 in-lbs (2.3-4.5 Nm).

INSTALLATION

10.

Verify that rubber seal is properly seated around perime-

ter of air cleaner cover.

1. Install new O-rings in grooves around breather bolt

11.

Fit air cleaner cover into backplate. Apply a small dab of

holes on inboard side of backplate.

Loctite Medium Strength Threadlocker

243 (blue) to

2. Aligning flat edge of gasket with molded tab, install new

threads of large allen head socket screw. Install screw in

gasket on inboard side of backplate. On California mod-

center of air cleaner cover and tighten to 36-60 in-lbs

els, install gasket by aligning small holes with plastic

(4.1-6.8 Nm).

pins.

3. On California models, push clean air inlet tube (to char-

coal canister) into hole on inboard side of backplate.

4. Align holes in backplate with those in cylinder heads and

install cylinder head breather bolts. Using a 7/16 inch

deepwell socket, alternately tighten bolts to

120-

144 in-lbs (13.6-16.3 Nm).

5. Slide new gasket over sleeve on inboard side of filter

element. Be sure holes in gasket are aligned with those

in filter.

6. Insert breather tubes about 1/4 inch (6.4 mm) into holes

on inboard side of filter element.

7. Install breather tubes onto fittings of two cylinder head

breather bolts.

2005 Touring: Fuel

4-17

HOME

VACUUM OPERATED FUEL VALVE (CARBURETED)

4.6

GENERAL

f1723x4x

A fuel valve is located under the fuel tank on the left side of

the motorcycle. The gasoline supply to the carburetor is

dependent upon the position of the valve handle as well as

the internal workings of the vacuum-operated valve.

To access the main fuel supply, turn the valve handle down

to the fully vertical position, so that the indicator points up to

ON. To access the reserve supply, turn the handle up to the

fully vertical position, so that the indicator points down to

RES(ERVE). Move the handle to the horizontal position to

shut the gasoline supply to the carburetor OFF. Always turn

the valve to the OFF position to refuel, or whenever the

engine is not running.

Gasoline will not flow through the fuel valve until the following

conditions are met:

The valve handle must be turned to the ON or

RES(ERVE) position.

A vacuum of approximately 0.5-1.0 inches of Mercury

(Hg) must be applied to the vacuum fitting at the back of

the fuel valve.

In service, the vacuum fitting is connected to the intake man-

ifold. The partial vacuum applied at the fitting creates a differ-

ence in pressure between the front side of the diaphragm

(which is vented to the atmosphere via the bottom fitting on

the fuel valve) and the rear. This pressure differential causes

the diaphragm to move against an internal spring, thereby

opening an orifice that enables the flow of gasoline to the

carburetor. When the vacuum at the vacuum fitting is

removed, the internal spring pressure closes the orifice,

which effectively halts the supply of fuel to the carburetor.

Valve Handle

Vacuum Fitting

Fuel Outlet Fitting

Jam Nut

Hose Clamp

Filter Strainer

Carburetor Fuel

Gasket

TROUBLESHOOTING

Inlet Hose

10.

Atmospheric

Convoluted Tubing

Pressure Port

If the fuel valve is not functioning properly, refer to the trou-

bleshooting chart on the next page.

Figure 4-14. Vacuum Operated Fuel Valve

Turn the handle of the fuel valve to OFF.

REMOVAL

1WARNING

DRAINING FUEL TANK

A small amount of gasoline may drain from the carbure-

tor fuel inlet hose when disconnected from the fuel valve

1WARNING

fitting. Thoroughly wipe up any spilled fuel immediately

and dispose of rags in a suitable manner. Gasoline is

Gasoline is extremely flammable and highly explosive.

extremely flammable and highly explosive. Inadequate

When servicing the fuel system, do not smoke or allow

open flame or sparks in the vicinity. Inadequate safety

safety precautions could result in death or serious

injury.

precautions could result in death or serious injury.

4-18

2005 Touring: Fuel

HOME

2. Using a side cutters, cut clamp and remove hose from

CLEANING AND INSPECTION

fuel outlet fitting at the front of the fuel valve. See Figure

4-14. Drain free end of hose into a suitable container.

1. Clean or replace the fuel filter strainer.

3. Remove elbow of intake manifold vacuum tube from fit-

2. Flush the tank. See Section 4.7 FUEL TANK (CARBU-

ting on inboard side of the fuel valve.

RETED), CLEANING AND INSPECTION.

4. Attach a length of fuel hose to the fuel outlet fitting. The

hose must be long enough to reach a suitable gasoline

container.

INSTALLATION

5. Turn the handle of the fuel valve to RES(ERVE).

6. Using the correct hose adapter, connect the Mity-Vac®

Install a new gasket on the valve head.

Hand Pump (HD-23738A) to the vacuum fitting.

Install the fuel filter strainer fitting the internal tube into

the larger hole in the valve head.

CAUTION

Clean threads and sealing surface of fuel tank adapter

and inspect for damage. Replace if necessary. See

To avoid damage to the diaphragm of the fuel valve, do

not apply a vacuum greater than 25 inches of Mercury

FUEL TANK ADAPTER on the next page.

(Hg) to the vacuum fitting.

With the hex side down, turn the jam nut two full turns in

a counterclockwise direction to thread onto fuel tank

Gently apply a vacuum of 1-10 inches of Mercury (Hg) to

adapter.

the vacuum fitting to get a good flow of gasoline through

the valve.

Insert fuel filter strainer into fuel tank. Holding the hex

jam nut to prevent rotation, turn the fuel valve two full

When the fuel tank is completely drained, remove the

turns in a clockwise direction to thread onto hex jam nut.

Mity-Vac® Hand Pump from the vacuum fitting.

Holding fuel tank adapter, turn the hex jam nut in a

1WARNING

clockwise direction to remove the fuel valve assembly.

10.

Remove the fuel filter strainer from the valve head.

Do not thread fuel valve onto hex jam nut more than two

turns or nut may “bottom” on valve, a condition which

11.

Remove the hex jam nut from the fuel valve.

may result in a gasoline leak. Any gasoline leak is a

12.

Remove the gasket from the valve head. Discard the

potential fire hazard that could result in death or serious

gasket.

injury.

Table 4-2. Troubleshooting Vacuum Operated Fuel Valve

Problem

Cause

Solution

1. Vacuum valve not opening.

1.1

Hose not connected to

1.1.1

Connect hose to vacuum fitting.

vacuum fitting.

1.2

Leaking diaphragm.

1.2.1

Replace fuel valve assembly.

1.3

Hose connected to

1.3.1

Connect hose to vacuum fitting.

atmospheric pressure port.

1.4

Vacuum hose assembly

1.4.1

Replace vacuum hose assembly.

pinched or cracked.

2. Vacuum valve does not close.

2.1

Damaged sealing surface on

2.2.1

Replace fuel valve assembly.

valve side of diaphragm.

2.2

Plugged vacuum fitting.

2.2.2

Clean as necessary.

2.3

Broken or missing internal

2.3.1

Replace fuel valve assembly.

spring.

Valve leaks gasoline at

3.1

Leaking diaphragm.

3.1.1

Replace fuel valve assembly.

atmospheric pressure port.

3.2

Loose diaphragm housing

3.2.1

Tighten screws.

screws.

2005 Touring: Fuel

4-19

HOME

Holding the fuel valve to prevent rotation, turn the hex

jam nut in a counterclockwise direction until snug.

f2052x4x

Tighten the hex jam nut to 15-20 ft-lbs (20.3-27.1 Nm).

Fuel Tank

Side

CAUTION

Do not allow dirt or fluids to get into the vacuum tube

that connects the fuel valve to the intake manifold. Con-

taminants can block the vacuum signal which could

O-Ring

cause the fuel valve to malfunction.

Connect elbow of intake manifold vacuum tube to fitting

on inboard side of the fuel valve.

Figure 4-15. Fuel Tank Adapter

Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet fitting at front of fuel

valve. Crimp clamp using HOSE CLAMP PLIERS (HD-

FUEL TANK ADAPTER

97087-65B).

Turn the handle of the fuel valve to OFF and fill the fuel

If leakage or damage is observed at the fuel tank adapter,

tank. Carefully inspect for leaks at fitting.

replace O-ring and/or adapter as follows:

10.

Turn the valve handle to ON and start engine. No priming

Remove fuel valve assembly. See REMOVAL in this sec-

or special procedures are required to start fuel flow.

tion.

Carefully inspect for leaks at fitting.

Slide a 7/8 inch socket over hex on adapter, and looking

11.

Stop engine and return the valve to the OFF position.

down at top of fuel tank, rotate in a clockwise direction to

remove. See Figure 4-15.

Remove O-ring from adapter. Discard O-ring.

Apply a very thin film of clean H-D 20W50 engine oil to

new O-ring. Install O-ring into groove of adapter.

Hand thread adapter into fuel tank bore. Looking down at

top of fuel tank, rotate adapter in a counterclockwise

direction until snug.

Slide a 7/8 inch socket over hex and tighten to 22-26 ft-

lbs (30-35 Nm).

Install fuel valve assembly. See INSTALLATION in this

section.

4-20

2005 Touring: Fuel

HOME

FUEL TANK (CARBURETED)

4.7

COMPLETE REMOVAL

f1924x8x

NOTE

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

INJECTED) for removal and installation instructions.

FLHT/C

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

Fuel Tank

1WARNING

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

Fuel Vapor

Fuel Tank Harness

Vent Tube

Connector [13]

(To Vapor Valve)

Not Present on FLHR/C/S

1WARNING

Figure 4-16. Fuel Level Sender Connector (FLHT/C)

Gasoline is extremely flammable and highly explosive.

When servicing the fuel system, do not smoke or allow

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

1WARNING

Drain the fuel tank. See Section 4.6 VACUUM OPER-

A small amount of gasoline may drain from the cross-

ATED FUEL VALVE (CARBURETED), DRAINING FUEL

over hose when disconnected from the fuel tank. Thor-

TANK, steps 1-8.

oughly wipe up any spilled fuel immediately and dis-

Carefully cut anchored cable strap securing main har-

pose of rags in a suitable manner. Gasoline is extremely

ness bundles, fuel level sender conduit, and fuel vapor

flammable and highly explosive. Inadequate safety pre-

cautions could result in death or serious injury.

vent tube to left side of frame backbone.

Disconnect fuel tank harness connector [13], 3-place

11. Using a side cutters, cut clamp from one end of cross-

Multilock, in front of battery. See Figure 4-16.

over hose beneath fuel tank. Drain free end of hose into

a suitable container.

Open fuel door on console. Remove two Allen head

screws inboard of rubber bumpers. These screws secure

12. Remove fuel tank from motorcycle.

console to clip nuts on the canopy bracket.

Remove Allen head screw to detach flange at rear of

console from clip nut on fuel tank weldment.

FLHR/S

Lay a clean shop cloth on forward part of rear fender.

Remove filler cap from neck of fuel tank. Remove con-

Remove seat. See Section 2.24 SEAT, REMOVAL.

sole and lay upside down on shop cloth. Reinstall filler

cap.

1WARNING

Gently pry fuel vapor vent tube from fitting on filler neck

To protect against shock and accidental start-up of vehi-

of fuel tank. Exercise caution to avoid pulling fitting from

cle, disconnect the negative battery cable before pro-

filler neck.

ceeding. Inadequate safety precautions could result in

10.

Remove two fuel tank front mounting bolts (with flat

death or serious injury.

washers) from left and right side of frame. Remove bolt

(with flat washer) to free rear of fuel tank from frame

Unthread bolt and remove battery negative cable (black)

backbone.

from battery negative (-) terminal.

2005 Touring: Fuel

4-21

HOME

CLEANING AND INSPECTION

1WARNING

Gasoline is extremely flammable and highly explosive.

Inspect the fuel tank for leaks and other damage.

When servicing the fuel system, do not smoke or allow

Replace damaged tanks that cannot be successfully

open flame or sparks in the vicinity. Inadequate safety

repaired.

precautions could result in death or serious injury.

If sludge, rust or varnish deposits are evident, clean fuel

3. Drain the fuel tank. See Section 4.6 VACUUM OPER-

tank as follows:

ATED FUEL VALVE (CARBURETED), DRAINING FUEL

TANK, steps 1-8.

1WARNING

4. Remove two fuel tank front mounting bolts (with flat

Even with the fuel tank completely drained, a small

washers) from left and right side of frame. Remove bolt

amount of gasoline may leak from the bore when the fuel

(with flat washer) to free rear of fuel tank from frame

valve is loosened or removed. Thoroughly wipe up any

backbone. On FLHRS models, removal of rear bolt also

spilled fuel immediately and dispose of rags in a suitable

releases instrument console bracket.

manner. Gasoline is extremely flammable and highly

5. Carefully cut anchored cable strap securing main har-

explosive. Inadequate safety precautions could result in

ness bundle, instrument console conduit, and fuel vapor

death or serious injury.

vent tube to left side of frame backbone.

a. Remove the fuel valve assembly and plug fuel tank

6. Remove acorn nut from instrument console. If present,

opening. See Section

4.6 VACUUM OPERATED

also remove Phillips screw and large flat washer (absent

FUEL VALVE (CARBURETED), REMOVAL.

on FLHRS models).

b. Remove canopy as follows:

7. Raise instrument console and bend back flexible clamp

FLHT/C, FLTR: See Section 8.29 FUEL LEVEL

on canopy to release main harness conduit. Depress

SENDER (CARBURETED), FLHT/C CANOPY,

button on socket side and remove fuel level sender con-

REMOVAL, steps 11-13.

nector [141], 3-place Mini-Deutsch.

FLHR: See Section 8.29 FUEL LEVEL SENDER

(CARBURETED), FLHR/S CANOPY, REMOVAL,

CAUTION

steps 10-12.

When removing instrument console, exercise caution to

avoid damaging speedometer unit. Wrap console in a

1WARNING

clean, dry shop towel to prevent damage.

An open flame or spark may cause a fuel tank explosion

Secure instrument console to top of rear fender using

if all traces of fuel are not purged from the tank. Use

bungee cords.

extreme caution when servicing fuel tanks. Inadequate

9. Remove console mounting bolt from slot at top of can-

safety precautions could result in death or serious injury.

opy.

c. Fill the tank with commercial cleaning solvent or a

10. Gently pry fuel vapor vent tube from fitting.

soap and water solution. Shake the tank to agitate

the cleaning agent.

11. At bottom left side of fuel tank, gently pull on convoluted

tubing to draw fuel gauge connector [117], 4-place Mul-

tilock, out of tunnel. Depress button on socket terminal

1WARNING

side and pull apart pin and socket halves.

To assist in loosening deposits, use only non-ferrous

metal balls (such as lead pellets) with fuel tank cleaning

1WARNING

solutions. The use of ferrous materials may cause a

spark, which can then ignite fuel vapors inside the tank.

A small amount of gasoline may drain from the crossover

The resulting flames or explosion could result in death or

hose when disconnected from the fuel tank. Thoroughly

serious injury.

wipe up any spilled fuel immediately and dis-pose of rags

in a suitable manner. Gasoline is extremely flammable

d. If necessary, non-ferrous metallic balls or pellets

and highly explosive. Inadequate safety precautions

may be added to the tank to help loosen deposits.

could result in death or serious injury.

e. Thoroughly flush the fuel tank after cleaning. Allow

12. Using a side cutters, cut clamp from one end of cross-

tank to air dry.

over hose beneath fuel tank. Drain free end of hose into

Install fuel valve assembly. See Section 4.6 VAC-

a suitable container.

UUM OPERATED FUEL VALVE (CARBURETED),

13. Remove fuel tank from motorcycle.

INSTALLATION.

4-22

2005 Touring: Fuel

HOME

Slide new clamp onto free end of carburetor fuel inlet

hose. Install hose onto fuel outlet fitting at side of fuel

Hose Cutter

valve. Crimp clamp.

Part No. HD-41185

Install the intake manifold vacuum hose onto the vacuum

fitting at the back of the fuel valve.

Start fuel tank front mounting bolts (with flat washers)

into left and right side of frame.

Hose Clamp Pliers

Part No. HD-97087-65B

Install bolt (with flat washer) to secure rear of fuel tank to

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

27 Nm).

Connect fuel vapor vent tube to fitting on filler neck of

fuel tank.

Remove filler cap. Position console on canopy. Route

Figure 4-17. Hose Cutter/Hose Clamp Pliers

cables from beneath console as shown in Figure 4-18.

Be sure that hoses and wires are not pinched by the

console during installation. Reinstall filler cap.

g. Install canopy as follows:

10.

Install Allen head screw to fasten rear flange of console

FLHT/C, FLTR: See Section 8.29 FUEL LEVEL

to clip nut on fuel tank weldment. Tighten screw to 25-30

SENDER (CARBURETED), FLHT/C CANOPY,

in-lbs (2.8-3.4 Nm).

INSTALLATION, steps 1-3.

FLHR: See Section 8.29 FUEL LEVEL SENDER

11.

Open fuel door on console. Install two Allen head screws

(CARBURETED), FLHR/S CANOPY, INSTALLA-

to secure front of console to clip nuts on canopy bracket.

TION, steps 1-3.

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Inspect crossover hose for cuts, cracks, nicks or other

damage. Be sure aging has not caused the hose to

become hard and brittle. If replacing from bulk storage,

use SAE R9 or equivalent fuel hose only. Remove old

hose and cut new hose to same length using HOSE

Fuel

Tank

CUTTER (HD-41185). See Figure 4-17.

Console

INSTALLATION

Fuel Level

(AFTER COMPLETE REMOVAL)

Sender Conduit

FLHT/C

Fuel

Overflow

Fuel Vapor

Hose

CAUTION

Vent Tube

(To Vapor Valve)

Exercise caution to avoid pinching wire harness be-

tween fuel tank and vehicle frame. Wire damage may

Main

result in electrical problems.

Harness

1. Work fuel tank into position aligning front flange holes

Bundle

Anchored

Main

with those in frame.

Cable Strap

Harness

Slide new clamp onto free end of crossover hose. Run-

Bundle

f1739b9x

ning hose beneath frame backbone, install hose onto fit-

ting at bottom front of fuel tank. Crimp clamp using

Figure 4-18. Console Cable/Hose Routing -FLHT/C, FLTR

HOSE CLAMP PLIERS (HD-97087-65B). See Figure 4-

17.

(Top View)

2005 Touring: Fuel

4-23

HOME

12. Connect fuel tank harness connector [13], 3-place Mul-

tilock, in front of battery. See Figure 4-16.

13. Snap anchor of new cable strap into hole on left side of

Convoluted

frame backbone. Tighten cable strap capturing main har-

Tubing

ness bundles, fuel level sender conduit, and fuel vapor

vent tube. Cut any excess cable strap material.

NOTE

Route fuel overflow hose inboard of wire bundles on right side

of frame, but do not capture in cable straps. See Figure 4-18.

14. Insert bolt through battery negative cable (black) into

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

8870

15. Install seat. See Section 2.24 SEAT, INSTALLATION.

Figure 4-19. Fuel Gauge (FLHR/S)

16. Turn the handle of the fuel valve to OFF and fill the fuel

tank. Carefully inspect for leaks. Turn the valve handle to

ON and start engine. Repeat inspection.

11.

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

27 Nm).

17. Stop engine and return the valve to the OFF position.

12.

Install acorn nut at top of instrument console and tighten

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phil-

lips screw and large flat washer (absent on FLHRS mod-

FLHR/S

els). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

13.

Connect fuel gauge to main harness. Route pin housing

CAUTION

and convoluted tubing forward and then inboard between

front of crossover hose fitting and bottom of fuel tank.

Exercise caution to avoid pinching the wiring harness

Mate pin and socket halves of fuel gauge connector

between the fuel tank and vehicle frame. Wire damage

[117], 4-place Multilock. Feed connector into tunnel of

may result in electrical problems.

fuel tank. See Figure 4-19.

Work fuel tank into position aligning front flange holes

14.

Snap anchor of new cable strap into hole on left side of

with those in frame.

frame backbone. Tighten cable strap capturing main har-

ness bundle, instrument console conduit, and fuel vapor

Slide new clamp onto free end of crossover hose. Run-

vent tube. Cut any excess cable strap material.

ning hose beneath frame backbone, install hose onto fit-

ting at bottom front of fuel tank. Crimp clamp using

NOTE

HOSE CLAMP PLIERS (HD-97087-65B).

Route fuel overflow hose inboard of wire bundles on right side

Slide new clamp onto free end of carburetor fuel inlet

of frame, but do not capture in cable straps. See Figure 4-18.

hose. Install hose onto fuel outlet fitting at side of fuel

15. Insert bolt through battery negative cable (black) into

valve. Crimp clamp.

threaded hole of battery negative (-) terminal. Tighten

Install the intake manifold vacuum hose onto the vacuum

bolt to 60-96 in-lbs (6.8-10.9 Nm).

fitting at the back of the fuel valve.

16. Install seat. See Section 2.24 SEAT, INSTALLATION.

Connect fuel vapor vent tube to fitting at top of canopy.

17. Turn the handle of the fuel valve to OFF and fill the fuel

Slide head of console mounting bolt into slot at top of

tank. Carefully inspect for leaks. Turn the valve handle to

canopy.

ON and start engine. Repeat inspection.

18. Stop engine and return the valve to the OFF position.

Moving instrument console toward installed position,

install fuel level sender connector [141], 3-place Mini-

Deutsch, at top of canopy. Bend flexible clamp to capture

main harness conduit.

PARTIAL REMOVAL

Align hole in instrument console with console mounting

bolt and place into position on fuel tank.

NOTE

Start fuel tank front mounting bolts (with flat washers)

For fuel injected models, see Section 9.4 FUEL TANK (FUEL

into left and right side of frame.

INJECTED) for removal and installation instructions.

10.

Install bolt (with flat washer) to secure rear of fuel tank to

frame backbone. On FLHRS models, capture instrument

FLHT/C

console bracket during installation. Tighten bolt to 15-20

ft-lbs (20-27 Nm).

Remove seat. See Section 2.24 SEAT, REMOVAL.

4-24

2005 Touring: Fuel

HOME

Remove two fuel tank front mounting bolts (with flat

1WARNING

washers) from left and right side of frame. Remove bolt

(with flat washer) to free rear of fuel tank from frame

To protect against shock and accidental start-up of vehi-

backbone. On FLHRS models, removal of rear bolt also

cle, disconnect the negative battery cable before pro-

releases instrument console bracket.

ceeding. Inadequate safety precautions could result in

death or serious injury.

Carefully cut anchored cable strap securing main har-

ness bundle, instrument console conduit, and fuel vapor

Unthread bolt and remove battery negative cable (black)

vent tube to left side of frame backbone.

from battery negative (-) terminal.

Remove acorn nut from instrument console. If present,

Carefully cut anchored cable strap securing main har-

also remove Phillips screw and large flat washer (absent

ness bundles, fuel level sender conduit, and fuel vapor

on FLHRS models).

vent tube to left side of frame backbone.

Raise instrument console and bend back flexible clamp

Disconnect fuel tank harness connector [13], 3-place

on canopy to release main harness conduit. Depress

Multilock, in front of battery. See Figure 4-16.

button on socket side and remove fuel level sender con-

Open fuel door on console. Remove two Allen head

nector [141], 3-place Mini-Deutsch.

screws inboard of rubber bumpers. These screws secure

console to clip nuts on the canopy bracket.

CAUTION

Remove Allen head screw to detach flange at rear of

When removing instrument console, exercise caution to

console from clip nut on fuel tank weldment.

avoid damaging speedometer unit. Wrap console in a

Lay a clean shop cloth on forward part of rear fender.

clean, dry shop towel to prevent damage.

Remove filler cap from neck of fuel tank. Remove con-

sole and lay upside down on shop cloth. Reinstall filler

Secure instrument console to top of rear fender using

cap.

bungee cords.

Gently pry fuel vapor vent tube from fitting on filler neck

Remove console mounting bolt from slot at top of can-

of fuel tank. Exercise caution to avoid pulling fitting from

opy.

filler neck.

Gently pry fuel vapor vent tube from fitting.

Remove two fuel tank front mounting bolts (with flat

10. At bottom left side of fuel tank, gently pull on convoluted

washers) from left and right side of frame. Remove bolt

tubing to draw fuel gauge connector [117], 4-place Mul-

(with flat washer) to free rear of fuel tank from frame

tilock, out of tunnel. Depress button on socket terminal

backbone.

side and pull apart pin and socket halves.

10.

Raise the fuel tank approximately 2 inches. Move the

11. Raise the fuel tank approximately 2 inches. Move the

fuel tank crossover hose to the rear of the ignition coil,

so that the tank can be raised an additional 2-3 inches.

Move fuel tank straight back and rest on frame back-

bone.

11.

Obtain three 1 x 2 inch wooden blocks. Raise the front of

the fuel tank off the frame backbone by placing one

12. Obtain three 1 x 2 inch wooden blocks. Raise the front of

the fuel tank off the frame backbone by placing one

block in the recess centered at the bottom of the tank. At

the rear of the tank, place two blocks in the recess, one

block in the recess centered at the bottom of the tank. At

the rear of the tank, place two blocks in the recess, one

block on top of the other.

FLHR/S

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

INSTALLATION

(AFTER PARTIAL REMOVAL)

1WARNING

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

FLHT/C

ceeding. Inadequate safety precautions could result in

Remove wooden blocks and move fuel tank toward its

death or serious injury.

installed position. Half way down, move fuel tank cross-

Unthread bolt and remove battery negative cable (black)

over hose in front of ignition coil. Work fuel tank into

from battery negative (-) terminal.

position aligning front flange holes with those in frame.

2005 Touring: Fuel

4-25

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