Harley Davidson 2005 touring models. Service repair manual — page 32

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IDLE AIR CONTROL

Idle Air

8495

Control

REMOVAL

1WARNING

The screws securing the idle air control flange to the

induction module have a loctite patch that may make

them very difficult to remove. Since a heat gun may be

needed to break down the loctite, remove induction

module from vehicle, so that heat is not applied close to

fuel tank. Gasoline is extremely flammable and highly

explosive. Inadequate safety precautions could result in

death or serious injury.

1. See INDUCTION MODULE, REMOVAL, in this section.

CAUTION

Figure 9-36. Induction Module (Rear View)

The idle air control screws have a loctite patch that may

make them very difficult to remove. If necessary, use a

f1938x9x

heat gun to break down the loctite. Apply heat evenly

around screw head in a circular motion. Do not direct

heat at idle air control and other components or damage

can occur.

Using a T20 TORX drive head, remove two screws to

release throttle cable bracket from induction module.

See Figure 9-34. Discard flange screw of idle air control.

Remove remaining screw to release flange of idle air

control from top of induction module. Discard screw.

Pull idle air control from bore of induction module.

O-Ring

Remove O-ring from body of idle air control. Discard O-

ring. See Figure 9-37.

Figure 9-37. Idle Air Control

INSTALLATION

Alternately tighten flange screws of idle air control to 25

1. Apply a thin coat of clean engine oil to new O-ring.

in-lbs (2.8 Nm).

Install O-ring on counterbore of induction module flange.

2. With the electrical connector facing the left side of the

Move free end of throttle return spring into slot in throttle

induction module (intake manifold side), install idle air

cable bracket.

control into bore.

See INDUCTION MODULE, INSTALLATION, in this sec-

3. Align hole in throttle cable bracket with hole at side of

tion.

induction module. Start screw into induction module.

See Figure 9-34.

4. Align hole at top of throttle cable bracket with thru hole in

flange of idle air control. Start new screw with loctite

patch into induction module.

5. Install remaining screw into flange of idle air control.

Again, use new screw with loctite patch.

6. Using a T20 TORX drive head, tighten screw at side of

throttle cable bracket to 27-33 in-lbs (3.0-3.7 Nm).

9-34

2005 Touring: Fuel Injection

HOME

Throttle Position Sensor

21.

Adapter Seal (2)

T20 TORX Screw- 14mm (3)

22.

Intake Manifold

T10 TORX Screw (2)

23.

O-Ring

Intake Air Temperature Sensor

24.

Throttle Body

Gasket

O-Ring

Idle Air Control

T20 TORX/Hex Screw (2)

Throttle Cable Bracket

10.

Fuel Injector

11.

T20 TORX Screw- 17mm (5)

12.

Fuel Rail

13.

Fuel Supply Tube Clamp

14.

Fuel Supply Tube

15.

Sealing Washer

16.

O-Ring

17.

Manifold Absolute

Pressure Sensor

18.

Rubber Seal

19.

Socket Head Screw (4)

20.

Flange Adapter (2)

f2161x9x

Figure 9-38. Induction Module Assembly

2005 Touring: Fuel Injection

9-35

HOME

NOTES

9-36

2005 Touring: Fuel Injection

Table Of Contents

SUBJECT

PAGE NO.

Appendix A-Tools

A-1

Appendix B-Wiring

B-1

Appendix C-Metric Conversions

C-1

Appendix D-Japan: Mainshaft/Countershaft

D-1

APPENDICES

HOME

TOOLS

A.1

Part No. B-45523 Valve Guide Reamer (7mm)

Part No. B-45655 Crankshaft/Sprocket Shaft

Bearing Remover/Installer Pilot/Driver

Use with HD-42720-5.

Part No. B-45524-1 Valve Guide Driver (7mm)

Part No. J-5586A Transmission Shaft

Use with B-45524-2A.

Retaining Ring Pliers

Part No. B-45524-2A Valve Guide Installer Sleeve (7mm)

Part No. HD-01289 Rim Protectors

Part No. B-45525 Valve Guide Hone (7mm)

Part No. HD-21000 Tire Spreader

Appendix A A-1

HOME

Part No. HD-23738A Mity-Vac Vacuum Pump

Part No. HD-26792 Spark Tester

Part No. HD-25070 Robinair Heat Gun

Part No. HD-33223-1 Cylinder Compression Gauge

Use with HD-41183.

HD-28431-6 Fluorescent Additive (6 1-oz. Bottles)

HD-28431-22 Fluorescent Additive (1 22-oz. Container)

Part No. HD-28431B Fluorescent Additive

Part No. HD-33413A Carburetor Idle Adjuster

(24 1-oz. Bottles). Use with HD-35457,

HD-47183 or HD-47184.

Part No. HD-28700 Tire Bead Expander

Part No. HD-33416 Universal Driver Handle

(12 Inch Length)

A-2

Appendix A

HOME

Part No. HD-34633 Air Suspension Pump and Gauge

Part No. HD-34751 Valve Guide Cleaning Brush

Part No. HD-34634 Fork Oil Seal Installer

Part No. HD-34902B Mainshaft Bearing Inner Race

Remover and Installer

Part No. HD-34730-2C Fuel Injector Test Lamp

Part No. HD-35316B Main Drive Gear Remover/Installer

and Main Drive Gear Bearing Installer

Part No. HD-34736B Valve Spring Compressor

Part No. HD-35381A Belt Tension Gauge

Appendix A A-3

HOME

CYLINDER LEAKDOWN TESTER

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CYLINDER LEAKDOWN TESTER

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Part No. HD-35381-3 Belt Tension Gauge Adapter

Part No. HD-35667A Cylinder Leakdown Tester

Part No. HD-35457 Black Light Leak Detector

Part No. HD-35758B Neway Valve Seat Cutter Set

Part No. HD-35500B Digital Multi-Meter

Part No. HD-37842A Main Drive Gear Needle Bearing

and Small Oil Seal Installer

Part No. HD-35518 Internal/External Retaining Ring Pliers

Part No. HD-38125-6 Packard Terminal Crimp Tool

(Sealed)

A-4

Appendix A

HOME

Part No. HD-38125-7 Packard Terminal Crimp Tool

Part No. HD-39361A Sprocket Shaft Oil Seal Installer

(Nonsealed)

Part No. HD-38125-8 Packard Terminal Crimp Tool

Part No. HD-39565 Engine Sound Probe

Part No. HD-39301A Steering Head Bearing

Part No. HD-39617 Inductive Amp Probe.

Race Remover. Use with HD-33416.

Use with HD-35500B.

Part No. HD-39302 Steering Head Bearing

Part No. HD-39621 Electrical Terminal Repair Kit

Race Installer

Appendix A A-5

HOME

Part No. HD-39621-27 AMP Socket Terminal Remover

Part No. HD-39787A Rivet Tool

Part No. HD-39621-28 AMP Pin Terminal Remover

Part No. HD-39800 Oil Filter Crusher (Small)

Part No. HD-39782A Cylinder Head Support Stand

Part No. HD-39823 Oil Filter Crusher (Large)

Part No. HD-39786 Cylinder Head Holding Fixture

Part No. HD-39847 Reamer T-Handle

A-6

Appendix A

HOME

Part No. HD-39964 Reamer Lubricant (Cool Tool)

Part No. HD-39994 Paint Repair Kit

Part No. HD-39965 Deutsch Terminal Crimp Tool

Part No. HD-41025A Tool Organizational System

Part No. HD-39969 Ultra Torch UT-100

Part No. HD-41137 Two-Way Hose Clamp Pliers

Part No. HD-39978 Fluke 78 Multimeter (DVOM)

Part No. HD-41155 VHS Tape Storage Tower

Use with HD-41198 and HD-44608.

Appendix A A-7

HOME

Part No. HD-41177 Fork Tube Holder

Part No. HD-41185 Hose Cutter

400

60 70

250

100

Part No. HD-41182 Fuel Pressure Gauge

Part No. HD-41185-1 Hose Cutter Blade

Part No. HD-41183 Robinair Heat Gun Shrink Tool

Part No. HD-41199-3 Idle Speed Control Actuator

Attachment. Use with HD-25070.

Test Lamp

Part No. HD-41184 Final Drive Sprocket Locking Tool

Part No. HD-41214 Primary Drive Locking Tool

A-8

Appendix A

HOME

Part No. HD-41354 Speedometer Tester

Part No. HD-41417 Propane Enrichment Kit

Part No. HD-41404A Harness Connector Test Kit

Part No. HD-41475 Deutsch Connector Service Kit

Includes HD-41475-100.

Part No. HD-41404-46 Dark Blue Pin Probes

Part No. HD-41475-100 Deutsch Connector Pick Tool

Use with HD-41404A.

Part No. HD-41405 Main Drive Gear Small Oil

Part No. HD-41496 Main Drive Gear Large Oil

Seal Installer

Appendix A A-9

HOME

Part No. HD-41609 Amp Multilock Terminal Crimp Tool

Part No. HD-42310-150 Drip Pan

Use with HD-42310.

Part No. HD-41771 Rotor Remover/Installer

Part No. HD-42311 Oil Filter Wrench

Part No. HD-42135 T-30 I.P. Torx Plus

Part No. HD-42313 Cam Chain Tensioner Unloader

Spoke Nipple Driver

With Retention Pins

Part No. HD-42310 Engine/Transmission Bench Stand

Part No. HD-42314 Crankshaft/Camshaft

Sprocket Locking Tool

A-10

Appendix A

HOME

Part No. HD-42315 Crankshaft Bushing

Part No. HD-42320A Piston Pin Remover

Remover/Installer

Part No. HD-42316 Crankshaft Bushing Reamer

Part No. HD-42322 Piston Support Plate

Part No. HD-42317A Piston Pin Circlip

Part No. HD-42324A Cylinder Torque Plates

Remover/Installer

Part No. HD-42318 Connecting Rod Bushing Reamer

Part No. HD-42325 Camshaft Needle Bearing

Remover/Installer

Appendix A A-11

HOME

Part No. HD-42326A Crankshaft Guide

Part No. HD-42720-5 Crankshaft/Sprocket Shaft

Bearing Remover/Installer Support Tube

Use with B-45655.

600

200

Made in USA

Part No. HD-42376 Battery/Charging System

Part No. HD-42879 Deutsch Solid Barrel Contact

Load Tester

Crimp Tool

Part No. HD-42569 Connecting Rod Bushing Hone

Part No. HD-42962 Breakout Box Adapters

Part No. HD-42682 Breakout Box (Carbureted)

Part No. HD-43293A Brake Caliper Piston Remover

Use with HD-39978.

A-12

Appendix A

HOME

Part No. HD-43644 Camshaft/Camshaft Bearing

Part No. HD-43876 Breakout Box (EFI)

Remover/Installer

Use with HD-39978.

Part No. HD-43645 Reamer Handle/Drive Socket

Part No. HD-44060 Wheel Bearing Remover/Installer

Part No. HD-43646A Engine Rolling Stand

Part No. HD-44061 Fuel Pressure Gauge Adapter

Part No. HD-43646-10 Drip Pan

Part No. HD-44067 Oil Filter Wrench

Use with HD-43646A.

Appendix A A-13

HOME

Part No. HD-44358 Flywheel Support Fixture

Part No. HD-44695 Mini Amp Multilock

Terminal Crimp Tool

Part No. HD-44567 Universal Driver Handle

Part No. HD-44750-P29 Panasonic Toughbook (Touch

(7 Inch Length)

Screen) and HD-44750-P50 Panasonic Toughbook

(Non-Touch Screen)

Part No. HD-44608 Radio Breakout Box

Part No. HD-45327 Rear Swingarm Bearing Installer

Use with HD-39978.

Part No. HD-44687 Ignition Coil Circuit Test Adapter

Part No. HD-45830 Tech Link

A-14

Appendix A

HOME

Part No. HD-45835 Road Test Kit

Part No. HD-45961 HDI Ignition Switch

Connector Remover

Part No. HD-45907 Universal Driver Handle

Part No. HD-45962 HDI Ignition Switch

(4 Inch Length)

Alignment Tool

Part No. HD-45928 Packard Micro 64 Terminal Remover

Part No. HD-45966 Fork Spring Compressing Tool

Part No. HD-45929 Packard Micro 64 Terminal Crimper

Part No. HD-45967 Shop Dolly

Use with HD-45968.

Appendix A A-15

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Harley Davidson 2005 touring models. Service repair manual — page 32

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