Harley Davidson 2004 Touring Models. Service Manual — page 57
HOME
14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
1WARNING
ASSEMBLY, EFI FUSES, INSTALLATION.
To protect against shock and accidental start-up of vehi-
15. Install seat. See Section 2.24 SEAT, INSTALLATION.
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
4.
Unthread bolt and remove battery negative cable (black)
INSTRUMENT CONSOLE/CANOPY
from battery negative (-) terminal.
5.
Carefully cut anchored cable strap securing main har-
ness bundle, instrument console conduit, and fuel vapor
FLHR/C/S/I
vent tube to left side of frame backbone.
REMOVAL
6.
Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRSI models).
1WARNING
7.
On FLHRSI models only, remove bolt (with flat washer)
to free rear of fuel tank from frame backbone. Removal
Gasoline will drain from the crossover hose when dis-
connected from the fuel tank. Thoroughly wipe up any
of rear bolt also releases instrument console bracket.
spilled fuel immediately. Dispose of rags in a suitable
8.
Raise instrument console and bend back flexible clamp
manner. Gasoline is extremely flammable and highly
on canopy to release main harness conduit. Depress
explosive. Inadequate safety precautions could result in
button on socket side and remove fuel level sender/fuel
death or serious injury.
pump connector [141], 3-place Mini-Deutsch.
CAUTION
CAUTION
Do not kink crossover hose or crimp shut using pliers or
When removing instrument console, exercise caution to
similar tool. Damage to the rigid inner lining will occur.
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
1.
Drain fuel tank as follows:
9.
Secure instrument console to top of rear fender using
Obtain a short section of hose with a 5/16 inch (7.9 mm)
bungee cords.
I.D. Insert bolt in one end of hose and install hose clamp
10.
Remove console mounting bolt from slot at top of can-
to ensure that end is securely plugged. Cut clamp from
opy.
one end of crossover hose beneath fuel tank. Quickly
replace crossover hose on fuel tank fitting with open end
11.
Gently pry fuel vapor vent tube from fitting at top of can-
of short hose while directing flow of gasoline from free
opy.
end of crossover hose into suitable container.
12.
Using a T20 TORX bit, remove ten screws around the
2.
Remove seat. See Section 2.24 SEAT, REMOVAL.
outer edge of the canopy. Discard screws.
13.
Raise canopy slightly to access top fitting (inlet port) at
back of fuel pressure regulator. Using a side cutters, cut
1WARNING
hose clamp and remove convoluted tube. Exercise cau-
The gasoline in the fuel supply line downstream of the
tion to avoid cutting or damaging tube or dropping
fuel pump is under high pressure (58 psi). To avoid an
pieces of cut clamp into fuel tank. See Figure 9-14.
uncontrolled discharge or spray of gasoline, always
14.
Remove canopy from fuel tank (with attached fuel pres-
purge the system of high pressure gas before the fuel
sure regulator, fuel filter canister, fuel pump and fuel
supply line is disconnected. Inadequate safety precau-
level sender).
tions could result in death or serious injury.
A spring-loaded hinge on the fuel pump bracket facili-
3. Purge the fuel supply line of high pressure gas. Proceed
tates removal of the assembly. For best results, press
as follows:
down on top of fuel pump with index finger or end of
screwdriver, and after raising canopy slightly, rotate on
a. Remove the 15 amp fuel pump fuse. See Figure 9-
hinge in a counterclockwise direction. When canopy is at
10. If necessary, see Section
9.2 ELECTRICAL
a 45˚ angle to top of fuel tank, carefully pull assembly
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
from left side lobe of fuel tank. See Figure 9-16.
b. Start the engine and allow the vehicle to run.
15.
Remove and discard canopy gasket. Verify that sealing
c. When the engine stalls, operate starter for 3 sec-
devices from screws are not lodged in canopy holes.
onds to remove remaining fuel from fuel lines.
Remove and discard devices if present.
9-18
2004 Touring: Fuel Injection
HOME
INSTALLATION
8.
Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3-
1. Obtain new canopy gasket. With the locator bump on the
place Mini-Deutsch, at top of canopy. Bend flexible
gasket OD toward the front, position gasket at bottom of
clamp to capture main harness conduit.
canopy. Start four nubs on gasket into holes in canopy.
9.
Align hole in instrument console with console mounting
Moving to top of canopy, alternately grasp each nub and
bolt and place into position on fuel tank.
pull through hole.
10.
Install acorn nut at top of instrument console and tighten
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
CAUTION
Phillips screw and large flat washer (absent on FLHRSI
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
11.
On FLHRSI models only, install bolt (with flat washer) to
to the right of the fuel gauge drain tube or it will be bent
secure rear of fuel tank and instrument console bracket
during installation of the canopy. A bent float rod will
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
result in erroneous gauge readings.
Nm).
12.
Snap anchor of new cable strap into hole on left side of
2. While holding fuel pump stationary, raise canopy slightly
frame backbone. Tighten cable strap capturing main har-
and rotate on hinge 90˚ in a counterclockwise direction.
ness bundle, instrument console conduit, and fuel vapor
3. Holding assembly so that canopy is at a 45˚ angle to top
vent tube. Cut any excess cable strap material.
of fuel tank, insert assembly into left side lobe of fuel
13.
Slide new clamp onto free end of crossover hose. Run-
tank keeping the float rod positioned to the right of the
ning hose beneath frame backbone, install hose onto fit-
fuel gauge drain tube. The spring-loaded hinge on the
ting at bottom front of fuel tank. Crimp clamp.
fuel pump bracket automatically returns assembly to its
14.
Insert bolt through battery negative cable (black) into
installed position inside fuel tank.
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
CAUTION
15.
Install the 15 amp fuel pump fuse. See Figure 9-10. If
Carefully inspect end of convoluted tube for cuts, tears,
necessary, see Section 9.2 ELECTRICAL BRACKET
holes or other damage. Replace tube if any damage is
ASSEMBLY, EFI FUSES, INSTALLATION.
found. Even the smallest hole can cause a reduction in
16.
Install seat. See Section 2.24 SEAT, INSTALLATION.
fuel pressure.
4. Raise canopy slightly and slide new hose clamp onto
free end of convoluted tube. Install tube onto top fitting
FUEL FILTER CANISTER
(inlet port) at back of fuel pressure regulator. Crimp
clamp. See Figure 9-14.
Replace the fuel filter canister every 25,000 miles (40,000
km) . Proceed as follows:
1WARNING
Always use new screws when installing the canopy.
REMOVAL
Reusing old screws may compromise sealing integrity
resulting in gas leaks. Gas leakage can cause fire or
1.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
explosion which could result in death or serious injury.
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
NOTE
2.
Release fuel filter canister as follows:
Check canopy screws for proper sealing devices. Screws
must have a bonded seal on underside of head. Replace
a. Pull wireform to release from slots on fuel filter can-
screws if seal is missing or damaged. See Figure 9-15.
ister bracket. See A of Figure 9-17.
b. Use hinge to swing wireform out of the way. Move
5.
While pushing down on the canopy, align holes in can-
canister bracket forward to disengage tab from slot
opy with those in fuel tank. Hand start ten new T20
on canopy weldment. See B of Figure 9-17.
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
c. Pull fitting on canister from fuel pressure regulator
Figure 9-15.
assembly. See C of Figure 9-17.
3.
Using a side cutters, cut hose clamp and remove convo-
6.
Connect fuel vapor vent tube to fitting at top of canopy.
luted tube from inlet port at side of fuel filter canister.
7.
Slide head of console mounting bolt into slot at top of
Exercise caution to avoid cutting or damaging tube. Dis-
canopy.
card fuel filter canister.
2004 Touring: Fuel Injection
9-19
HOME
INSTALLATION
A
CAUTION
Do not replace tubes inside of fuel tank with ordinary
bulk hose. All internal lines must be replaced with the
special original equipment convoluted nylon tubes. Bulk
hose will degrade when immersed in gasoline (particu-
larly stale gasoline), resulting in contamination of the
fuel supply. Use of contaminated fuel will cause starting
and driveability problems and possible vehicle damage.
1.
If present, remove and discard plastic caps from fittings
of new fuel filter canister.
2.
Slide new hose clamp onto free end of convoluted tube
(from fuel pump). Install tube onto inlet port at side of
f1940x9x
fuel filter canister. If necessary, use a little isopropyl
alcohol or glass cleaner to aid installation. Crimp clamp.
Pull wireform from slots in canister bracket.
3.
Install fuel filter canister as follows:
a. Install new O-ring onto fitting of fuel filter canister.
B
Insert fitting into fuel pressure regulator assembly,
so that inlet port is on fuel pump side. See C of Fig-
ure 9-17.
b. Slide tab on canister bracket into slot of canopy
weldment until bump on bracket engages depres-
sion at side of canister. See B of Figure 9-17.
c. Use hinge to rotate wireform over canister bracket.
Press on wireform until it fully engages slots on can-
ister bracket. See A of Figure 9-17.
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
f1945x9x
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
Pull canister bracket from canopy weldment.
fuel pressure.
4.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
C
OPY, FLHR/C/S/I, INSTALLATION.
FUEL PRESSURE REGULATOR
REMOVAL
1.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2.
See FUEL FILTER CANISTER, REMOVAL, step 2.
f1944x9x
3.
Slide fuel pressure regulator assembly forward to free
arms from catches on canopy weldment. See Figure 9-
Pull canister from fuel pressure regulator.
18.
Figure 9-17. Remove Fuel Filter Canister (FLHR/C/S/I)
9-20
2004 Touring: Fuel Injection
HOME
5.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
OPY, FLHR/C/S/I, INSTALLATION.
FUEL PUMP
REMOVAL
1.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2.
Depress external latch and remove electrical connector
at top of fuel pump.
3.
Using a side cutters, cut hose clamp and pull convoluted
f1943x9x
tube from fuel pump outlet port. Exercise caution to
avoid cutting or damaging tube (and cracking or break-
Figure 9-18. Remove Fuel Pressure Regulator
ing outlet port).
(FLHR/C/S/I)
4.
Remove T15 TORX screw and pull fuel level sender from
post on fuel pump bracket.
5.
Release end of return spring from hook on fuel pump
bracket.
CAUTION
Be absolutely certain fuel pump is faulty before remov-
ing hinge from support arm. Hinge is damaged during
Housing
removal and requires replacement of the fuel pump and
bracket assembly.
O-Ring
6.
Insert flat tip screwdriver at location shown in Figure 9-
f1931x9x
20. Carefully crack plastic webbing at top of hinge and
remove from support arm. Discard fuel pump and
Figure 9-19. Fuel Pressure Regulator Assembly
bracket assembly.
7.
Inspect the condition of the fuel pump wiring. If the wir-
ing needs to be replaced, see FUEL PUMP/FUEL
4.
Remove fuel pressure regulator from housing. To over-
LEVEL SENDER WIRING on the next page.
come the resistance of two O-rings, insert blade of small
screwdriver into gap between regulator and housing and
gently pry regulator out. See Figure 9-19.
8399
5.
Inspect O-rings for cuts, tears or general deterioration.
Screwdriver
Replace the O-rings if they have taken a definite set.
INSTALLATION
1. Apply a thin coat of clean engine oil to new O-rings.
Install O-rings in grooves of fuel pressure regulator. See
Figure 9-19.
2. Install fuel pressure regulator into housing.
3. Fit fuel pressure regulator assembly into canopy weld-
ment engaging arms in catches. See Figure 9-18.
4. See FUEL FILTER CANISTER, INSTALLATION, step 3.
Figure 9-20. Crack Hinge to Remove From Support Arm
2004 Touring: Fuel Injection
9-21
HOME
INSTALLATION
f1946x9x
1.
Obtain new fuel pump and bracket assembly. Install new
hinge at top of fuel pump bracket, so that opening of
support arm slot is on the fuel level sender mount side.
2. Slide end of support arm into slot at top of hinge. Pull on
Push
hinge to verify that it is locked by pin on support arm.
Install free end of return spring onto hook on fuel pump
bracket.
Pull
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
3.
Slide new hose clamp onto free end of convoluted tube
(to fuel filter canister inlet). Install tube onto outlet port of
fuel pump. Crimp clamp, but exercise caution to avoid
cracking or breaking outlet port.
To disengage tabs from windows, simultaneously
pull on one safety pin while pushing on the other.
4.
Install electrical connector at top of fuel pump. Gently
tug on connector to verify that external latch is locked
and connector will not come free of terminals.
Pull terminals from wire block and cut.
5.
Align two holes in fuel level sender with threaded hole
and post on fuel pump bracket. Install T15 TORX screw
in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).
6.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
OPY, FLHR/C/S/I, INSTALLATION.
FUEL PUMP/FUEL LEVEL SENDER
WIRING
CAUTION
Do not replace the special teflon coated fuel pump/fuel
f1930x9x
level sender wiring with ordinary bulk wire. Ordinary
insulation materials may deteriorate when in contact
Figure 9-21. Remove Wire Block and Cut Terminals
with gasoline.
NOTE
Damaged fuel pump and/or fuel level sender wiring requires
2. If present, cut cable strap to release wiring at bottom of
replacement of the fuel level sender unit. See FUEL LEVEL
support arm.
SENDER on this page.
3. Unwind spiral tubing from fuel pump and fuel level
sender wiring.
FUEL LEVEL SENDER
4. Depress external latch and remove electrical connector
at top of fuel pump.
5. At bottom of canopy, remove socket terminal from spade
REMOVAL
contact on connector clip.
1.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
6. Remove T15 TORX screw and pull fuel level sender from
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
post on fuel pump bracket.
FLHR/C/S/I, REMOVAL.
9-22
2004 Touring: Fuel Injection
HOME
7. Remove socket terminals from
3-place Mini-Deutsch
5.
Install electrical connector at top of fuel pump. Gently
connector on canopy. Proceed as follows:
tug on connector to verify that external latch is locked
and connector will not come free of terminals.
NOTE
6.
Wind spiral tubing around fuel pump (and fuel level
For additional clearance, pull wireform to release from slots
sender) wiring.
on fuel filter canister bracket, and then use hinge to swing
wireform out of the way. Move canister bracket forward to dis-
7.
Install new cable strap capturing wiring at bottom of sup-
engage tab from slot on canopy weldment. Remove socket
port arm. Cut any excess cable strap material.
terminal from spade contact on connector clip.
8.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
a. At underside of canopy, take note of the rectangular
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
opening or window on each side of the connector
OPY, FLHR/C/S/I, INSTALLATION.
body. Now take note of the tab inside each window.
b. Obtain two safety pins. On each side of connector
body, insert a safety pin between body and wire
CANOPY CONNECTOR/O-RING
block until end of each pin appears in window. To
disengage tabs from windows, gently pull on one
safety pin while pushing on the other. See upper
REMOVAL
frame of Figure 9-21. With tabs released, gently tug
on wires to release wire block from connector body.
1.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
c. Pull the wire socket terminals out of the wire block.
FLHR/C/S/I, REMOVAL.
See lower frame of Figure 9-21. Cut off the socket
terminals and back the wires out of the wire block.
2.
At bottom of canopy, remove socket terminal from spade
contact on connector clip.
d. Insert wire block back into connector body until tabs
lock in windows. One corner of wire block and con-
3.
Remove wire block from connector body as described
nector body is square to prevent improper installa-
under FUEL LEVEL SENDER, REMOVAL, steps 7(a)-
tion.
7(b), on this page.
4.
Slide connector clip from slots on connector body.
Remove connector body from canopy.
INSTALLATION
5.
Remove O-ring from groove on connector body.
1. Insert socket terminals of new wiring into wire block.
Take note of the table below for wire locations.
INSTALLATION
Table 9-2. Fuel Level Sender/Fuel Pump
1.
Apply a very thin film of clean H-D 20W50 engine oil to
Connector [141], 3-Place Mini-Deutsch
O-ring. Install O-ring in groove of connector body.
2.
Fit connector body into hole at top of canopy. At under-
Chamber
Wire Color
Function
side of canopy, install connector clip engaging slots in
1
Orange
Pump Power
connector body.
2
Yellow
Sender Output
3.
Insert wire block back into connector body until tabs lock
in windows. One corner of wire block and connector
3
Black
Ground
body is square to prevent improper installation.
4.
Install socket terminal onto spade contact on connector
NOTE
clip.
A series of dots are molded into the wire end of the block to
indicate wire location, one dot indicating chamber 1, two dots
5.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
chamber 2, three dots chamber 3. (Wire location numbers
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
are also stamped below the terminals inside the Mini-Deutch
OPY, FLHR/C/S/I, INSTALLATION.
pin housing.)
2. Gently tug on wires to verify that they will not back out of
wire block.
FUEL SUPPLY CHECK VALVE/TUBE
3. Install socket terminal onto spade contact on connector
clip.
NOTE
4. Align two holes in fuel level sender with threaded hole
The in-tank check valve is housed in the quick-connect fitting.
and post on fuel pump bracket. Install T15 TORX screw
The check valve prevents the fuel tank from draining when
in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).
the external supply line is disconnected.
2004 Touring: Fuel Injection
9-23
HOME
Convoluted
Tube
SUPPLY CHECK VALVE/TUBE
O-Ring
Body Hex
Chrome Sleeve
f2048x9x
Figure 9-22. Supply Check Valve (Quick-Connect Fitting)
REMOVAL
3. Slide a 7/8 inch deepwell socket over chrome sleeve
engaging hex on quick-connect fitting. See Figure 9-22.
1.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
Looking down at top of fuel tank, rotate fitting in a clock-
REMOVAL, steps 1-13, or INSTRUMENT CONSOLE/
wise direction until it turns easily. Remove the fitting by
CANOPY, FLHR/C/S/I, REMOVAL, steps 1-12.
hand drawing convoluted tube out through hole at bot-
tom of fuel tank.
1WARNING
A small amount of gasoline may drain from the fuel sup-
ply line when disconnected from the fuel tank. Thor-
oughly wipe up any spilled fuel immediately. Dispose of
INSTALLATION
rags in a suitable manner. Gasoline is extremely flamma-
ble and highly explosive. Inadequate safety precautions
could result in death or serious injury.
CAUTION
Carefully inspect convoluted tube for cuts, tears, holes
1WARNING
or other damage. Replace tube (with attached quick-con-
nect fitting) if any damage is found. Even the smallest
Exercise caution to avoid twisting the fuel supply line fit-
ting, as any cracks in the plastic construction of the line
hole can cause a reduction in fuel pressure.
can result in gas leaks. Gas leakage can cause fire or
1.
Apply a very thin film of clean H-D 20W50 engine oil to
explosion which could result in death or serious injury.
new O-ring. Slide O-ring down convoluted tube and into
2. Locate quick-connect fitting on left side of fuel tank. Pull
groove of new quick-connect fitting. See Figure 9-22.
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
2.
Feeding convoluted tube through hole at bottom of fuel
tank, hand thread quick-connect fitting into bore. Look-
1WARNING
ing down at top of fuel tank, rotate fitting in a counter-
clockwise direction until snug.
A small amount of gasoline may drain from the fuel tank
when the quick-connect fitting is removed. Thoroughly
3. Slide a 7/8 inch deepwell socket over chrome sleeve
wipe up any spilled fuel immediately. Dispose of rags in
engaging hex on quick-connect fitting. Tighten fitting to
a suitable manner. Inadequate safety precautions could
22-26 ft-lbs (29.8-35.3 Nm).
result in death or serious injury.
9-24
2004 Touring: Fuel Injection
HOME
1WARNING
1WARNING
Exercise caution to avoid twisting the fuel supply line fit-
To avoid an uncontrolled discharge or spray of gasoline,
ting, as any cracks in the plastic construction of the line
always be sure the quick-connect fitting is properly
can result in gas leaks. Gas leakage can cause fire or
mated. A slight tug on the fuel supply line fitting will ver-
explosion which could result in death or serious injury.
ify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
4.
Pull up on chrome sleeve of quick-connect fitting and
result in death or serious injury.
insert neck of fuel supply line fitting. While pushing up on
bottom of fitting, pull down on chrome sleeve until it
5.
See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
“clicks” into the locked position.
INSTALLATION, steps 4-15, or INSTRUMENT CON-
SOLE/CANOPY, FLHR/C/S/I, INSTALLATION, steps 4-
14.
2004 Touring: Fuel Injection
9-25
HOME
NOTES
9-26
2004 Touring: Fuel Injection
HOME
INDUCTION MODULE ASSEMBLY
9.5
2. Remove air cleaner and backplate. See Section 4.5 AIR
GENERAL
CLEANER, REMOVAL.
See Figure 9-23. The Induction Module Assembly consists of
3. Pull purge tube from fitting at top of induction module
the following components:
(California models only). See Figure 9-23.
● Induction Module
4. Using a needle nose pliers, carefully pull idle cable bar-
● Fuel Supply Line
rel from upper hole in throttle wheel. Pull throttle cable
● Fuel Rail/Fuel Supply Tube
barrel from lower hole. Using slots, release idle and
● Fuel Injectors
throttle cables from guides in throttle cable bracket.
● Intake Air Temperature Sensor
5. On cruise control equipped models, remove E-clip from
● Throttle Position Sensor
sleeve at end of cruise cable housing. Using slot,
● Manifold Absolute Pressure Sensor
remove cable housing from cable guide in throttle cable
● Idle Air Control
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. See Fig-
ure 9-24.
INDUCTION MODULE
6. Remove idle air control and manifold absolute pressure
sensor connectors. Pull external latch(es) outward and
use rocking motion to separate pin and socket halves.
REMOVAL
7. Depress wire form to remove electrical connectors from
front and rear fuel injectors.
1. Partially remove fuel tank. See Section 9.4 FUEL TANK
(FUEL INJECTED), PARTIAL REMOVAL, either FLHT/
8. Remove throttle position sensor and intake air tempera-
C/U/I, FLTRI or FLHR/C/S/I.
ture sensor connectors.
1.
Fuel Injector (Front)
1
Front
2.
Throttle Cable Bracket
2
3
3.
Idle Air Control
4.
Throttle Position Sensor
5.
Purge Tube Fitting
(California Models Only)
6.
Intake Air Temperature Sensor
7.
Manifold Absolute Pressure
Sensor
8.
Fuel Injector (Rear)
10
9.
Fuel Rail
10. Fuel Supply Tube
9
7
Rear
5
8
f2162x9x
6
4
Figure 9-23. Induction Module Assembly
2004 Touring: Fuel Injection
9-27
HOME
13. Remove seals from flange adapters. Discard seals.
Remove flange adapters from outlet ports of induction
f1965x8x
module.
14. If it should become necessary to split the induction mod-
ule, that is, separate the throttle body from the intake
manifold, proceed as follows:
a. Remove top and bottom T20 TORX screws to sepa-
rate intake manifold and throttle body flanges.
b. Remove O-ring from counterbore of throttle body
flange. Discard O-ring.
Wheel Pin
INSTALLATION
End Fitting
1.
If induction module was split, assemble the intake mani-
fold and throttle body as follows:
a. Apply a thin coat of clean engine oil to new O-ring.
Figure 9-24. Remove End Fitting From Wheel Pin
Install O-ring in counterbore of throttle body flange.
Mate intake manifold and throttle body flanges.
Button
b. Apply Loctite Wicking Threadlocker 290 (green) to
threads of two T20 TORX screws. Install screws and
alternately tighten to
27-33 in-lbs (3.1-3.7 Nm).
Allow approximately 3-6 hours to elapse for com-
pound to cure.
2.
Slide fuel supply line onto tube at top of induction mod-
ule. A slight tug will verify that the line is locked in place.
3.
Orientate the induction module as shown in Figure 9-23.
With the counterbore facing outward, slide cylinder head
f1922x9x
flange adapters onto outlet ports of induction module.
The flange adapters are not interchangeable. Look next
Figure 9-25. Remove Fuel Supply Line From Supply Tube
to the slotted bolt hole for a stamp that indicates F(ront)
and R(ear) cylinder.
9.
Remove right side allen head socket screws from front
4.
Place a new seal in each flange adapter with the bev-
and rear cylinder head flange adapters. For best results,
eled side in against the counterbore.
use a long 1/4 inch ball allen head socket with end driver
5.
Standing on right side of engine, slide induction module
4 inches long.
toward installed position so that open-ended slots on
10. Moving to opposite side of vehicle, just loosen left side
flange adapters begin to engage allen head socket
allen head socket screws from flange adapters. Slots in
screws loosely installed on left side. Use caution around
flanges make removal of left side screws unnecessary.
horn bracket to prevent damage to fuel line.
To better access bolts, loosen acorn nut and swing horn
6.
Install sleeve on throttle cable housing into shorter cable
assembly out of the way.
guide at top of throttle cable bracket. Drawing throttle
11. Slide induction module out from right side of vehicle.
cable downward, fit barrel end into lower hole in throttle
Use caution around horn bracket to prevent damage to
wheel. Install sleeve and spring on idle cable housing
fuel line.
into longer cable guide at bottom of throttle cable bracket
inserting barrel end into upper hole in throttle wheel.
1WARNING
7.
On cruise control equipped models, slide groove in
cruise cable end fitting over cap of wheel pin. Push on
A small amount of gasoline will drain from the fuel sup-
end fitting until it snaps in place. Using slot, slip cruise
ply line when disconnected from the supply tube. Thor-
cable housing into cable guide in throttle cable bracket.
oughly wipe up any spilled fuel immediately. Dispose of
Install new E-clip on sleeve at end of cruise cable hous-
rags in a suitable manner. Gasoline is extremely flamma-
ing.
ble and highly explosive. Inadequate safety precautions
8.
Align fixed holes in flange adapters with those in cylinder
could result in death or serious injury.
heads and start allen head socket screws. For best
12. Depress button on inboard side of fuel supply line and
results, use a long 1/4 inch ball allen head socket with
remove from supply tube. See Figure 9-25.
end driver 4 inches long.
9-28
2004 Touring: Fuel Injection
HOME
11.
Remove breather bolts and T27 TORX screws to remove
Breather Bolts
backplate, if installed.
f1966x9x
12.
Tighten allen head socket screws in fixed holes of flange
adapters to 96-144 in-lbs (10.9-16.3 Nm).
13.
Remove breather bolts to remove alignment bracket, if
installed.
14.
Install electrical connectors on fuel injectors.
15.
Install manifold absolute pressure sensor and idle air
control connectors.
16.
Install intake air temperature sensor and throttle position
sensor connectors.
17.
Connect purge tube to fitting at top of induction module
(California models only). See Figure 9-23.
18.
Install fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED), INSTALLATION
(AFTER PARTIAL
REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.
T27 TORX
Backplate
Screws
19.
Turn the Ignition/Light Key Switch to ON and then back
to OFF to reset idle air control to park position.
20.
Install backplate and air cleaner. See Section 4.5 AIR
f2079x9x
CLEANER, INSTALLATION.
21.
Check throttle and idle control cable adjustment. Check
cruise cable adjustment.
FUEL SUPPLY LINE
1WARNING
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
Bracket
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
Figure 9-26. Install Backplate or Bracket
supply line is disconnected. Inadequate safety precau-
tions could result in death or serious injury.
9.
Use the air cleaner backplate or INDUCTION SYSTEM
REMOVAL
ALIGNMENT BRACKET (P&A Part No. 40054-01) to
properly locate induction module. Proceed as follows:
1.
Partially remove fuel tank. See Section 9.4 FUEL TANK
(FUEL INJECTED), PARTIAL REMOVAL, FLHT/C/U/I,
a. Backplate: Install two breather bolts to fasten back-
FLTRI or FLHR/C/S/I.
plate to front and rear cylinder heads. Install three
T27 TORX screws to secure backplate to face of
induction module. See upper frame of Figure 9-26.
1WARNING
b. Alignment bracket: Fitting pins on inboard side
A small amount of gasoline will drain from the fuel sup-
into holes in face of induction module, install two
ply line when disconnected from the fuel tank. Thor-
breather bolts to fasten bracket to front and rear cyl-
oughly wipe up any spilled fuel immediately. Dispose of
inder heads. See lower frame of Figure 9-26.
rags in a suitable manner. Gasoline is extremely flamma-
ble and highly explosive. Inadequate safety precautions
10.
Tighten allen head socket screw in fixed holes of flange
could result in death or serious injury.
adapters until snug. Moving to left side of engine, tighten
screws in slotted holes to 96-144 in-lbs (10.9-16.3 Nm).
NOTE
If moved, swing horn assembly back into position and
Check valve in the fuel tank fitting impedes any further fuel
tighten acorn nut.
seepage once external fuel line has drained.
2004 Touring: Fuel Injection
9-29
HOME
FUEL RAIL/FUEL SUPPLY TUBE
Button
REMOVAL
1.
See INDUCTION MODULE, REMOVAL, in this section.
2.
Depress button on inboard side of fuel supply line and
remove from fuel supply tube. See Figure 9-27.
3.
Using a T20 TORX drive head, remove screw to release
fuel supply tube clamp. See Figure 9-28.
f1922x9x
4.
Gently pull fuel supply tube from fuel rail. Remove seal-
Figure 9-27. Remove Fuel Supply Line From Supply Tube
ing washer from end of fuel supply tube. Remove O-ring
from fuel rail bore. Discard sealing washer and O-ring.
2.
Pull up on chrome sleeve of quick-connect fitting on left
side of fuel tank and pull down on fuel supply line to dis-
connect. See Figure 9-24.
3.
Raise fuel tank approximately 2 inches. Move the fuel
Fuel Supply
Tube Clamp
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 slightly and rest on frame
backbone.
4.
Obtain several 1 x 2 inch wooden blocks. Raise the front
and rear of the fuel tank off the frame backbone by plac-
ing blocks in the recess centered at the bottom of the
tank.
1WARNING
A small amount of gasoline will drain from the fuel sup-
9407
ply line when disconnected from the supply tube at the
top of the induction module. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable
Figure 9-28. Remove Fuel Supply Tube Clamp
manner. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
T20 TORX
death or serious injury.
Screws
5. Depress button on inboard side of fuel supply line and
remove from supply tube. See Figure 9-27.
INSTALLATION
1.
Slide fuel supply line onto tube at top of induction mod-
ule. A slight tug will verify that the line is locked in place.
Fuel Rail
See Figure 9-27.
2.
Pull up on chrome sleeve of quick-connect fitting on left
side of tank and insert neck of fuel supply line fitting.
While pushing up on bottom of fuel supply line fitting,
pull down on chrome sleeve until it “clicks” into the
locked position. Tug on fuel supply line to be sure that it
will not come free.
8495
3.
Install fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED), INSTALLATION
(AFTER PARTIAL
Figure 9-29. Remove Fuel Rail
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
9-30
2004 Touring: Fuel Injection
HOME
FUEL INJECTORS
f1935x9x
Sealing
Washer
O-Ring
REMOVAL
1. See INDUCTION MODULE, REMOVAL, in this section.
2. Depress button on inboard side of fuel supply line and
remove from fuel supply tube. See Figure 9-27.
3. Using a T20 TORX drive head, remove screw to release
fuel supply tube clamp. See Figure 9-28.
Figure 9-30. Install Fuel Supply Tube
4. Using a T20 TORX drive head, remove two screws to
release fuel rail from induction module. See Figure 9-29.
5.
Pull fuel rail with attached fuel injectors from induction
5.
Using a T20 TORX drive head, remove two screws to
module. To overcome the resistance of the bottom O-
release fuel rail from induction module. See Figure 9-29.
ring on both fuel injectors, gently rock assembly back
6.
Pull fuel rail with attached fuel injectors from induction
and forth while pulling.
module. To overcome the resistance of the bottom O-
6.
Pull fuel injectors from fuel rail. To overcome the resis-
ring on both fuel injectors, gently rock assembly back
tance of the top O-ring, gently rock each fuel injector
and forth while pulling.
while pulling.
7.
Pull fuel injectors from fuel rail. To overcome the resis-
7.
Remove O-rings from fuel injectors. Discard O-rings.
tance of the top O-ring, gently rock each fuel injector
See Figure 9-31.
while pulling.
8.
Remove O-rings from fuel injectors. Discard O-rings.
See Figure 9-31.
INSTALLATION
1.
Apply a thin coat of clean engine oil to new injector O-
rings. Install O-rings on fuel injectors. See Figure 9-31.
INSTALLATION
2.
With the electrical connector topside, push fuel injectors
1.
Apply a thin coat of clean engine oil to new injector O-
into induction module bores. Rotate fuel injectors, so
rings. Install O-rings on fuel injectors. See Figure 9-31.
that the electrical connectors are on the outboard side.
2.
With the electrical connector topside, push fuel injectors
3.
Push fuel rail over fuel injectors until fuel rail flange con-
into induction module bores. Rotate fuel injectors, so
tacts boss on induction module.
that the electrical connectors are on the outboard side.
4.
Using a T20 TORX drive head, install two screws to fas-
3.
Push fuel rail over fuel injectors until fuel rail flange con-
ten fuel rail to induction module. Alternately tighten
tacts boss on induction module.
screws to 27-33 in-lbs (3.0-3.7 Nm). See Figure 9-29.
4.
Using a T20 TORX drive head, install two screws to fas-
ten fuel rail to induction module. Alternately tighten
screws to 27-33 in-lbs (3.0-3.7 Nm). See Figure 9-29.
O-Ring
5.
Note the collar on each end of the fuel supply tube. Slide
a new sealing washer down the shorter neck until it con-
tacts the collar. Slide a new o-ring down the tube until it
contacts the sealing washer. See Figure 9-30. Push tube
Electrical
into fuel rail bore until collar is flush with casting.
Connector
6.
Align hole in fuel supply tube clamp with hole in fuel rail.
Using a T20 TORX drive head, install screw and tighten
to 27-33 in-lbs (3.0-3.7 Nm). See Figure 9-28. Rotate
fuel supply tube so that it angles downward.
f1934x9x
7.
See INDUCTION MODULE, INSTALLATION, in this sec-
tion.
Figure 9-31. Fuel Injector
2004 Touring: Fuel Injection
9-31
HOME
5.
Align hole in fuel supply tube clamp with hole in fuel rail.
Using a T20 TORX drive head, install screw and tighten
8495
to 27-33 in-lbs (3.0-3.7 Nm). See Figure 9-28. Rotate
fuel supply tube so that it angles downward.
6.
See INDUCTION MODULE, INSTALLATION, in this sec-
tion.
INTAKE AIR TEMPERATURE
SENSOR
REMOVAL
Intake Air
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
Temperature
Throttle
Sensor
Position
MAXI-FUSE, REMOVAL.
Sensor
2. Remove air cleaner and backplate. See Section 4.5 AIR
CLEANER, REMOVAL.
Figure 9-32. Induction Module (Rear View)
3. Disconnect the intake air temperature sensor connector.
See Figure 9-32. Pull external latches outward and use
a rocking motion to separate pin and socket halves.
f1936x9x
Thermistor
4. Using a T10 TORX drive head, remove two screws to
release intake air temperature sensor from induction
module. See Figure 9-32.
5. Remove and discard gasket.
INSTALLATION
1. Place new gasket on flange of intake air temperature
Gasket
sensor.
2.
Insert sensor into induction module with electrical con-
Figure 9-33. Intake Air Temperature Sensor
nector facing toward the left side of the vehicle. See Fig-
ure 9-32.
3.
Using a T10 TORX drive head, install two screws to
secure intake air temperature sensor to induction mod-
3.
Disconnect the throttle position sensor connector. See
ule. Alternately tighten screws to 12 in-lbs (1.4 Nm).
Figure 9-32. Pull external latch outward and use a rock-
See Figure 9-32.
ing motion to separate pin and socket halves.
4.
Install the intake air temperature sensor connector.
4.
Using a T20 TORX drive head, remove two screws to
5.
Install backplate and air cleaner. See Section 4.5 AIR
release sensor from induction module. See Figure 9-32.
CLEANER, INSTALLATION.
6.
Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
INSTALLATION
1.
With electrical connector facing down, fit pocket of throt-
tle position sensor over throttle shaft.
THROTTLE POSITION SENSOR
2.
Align holes in flange of throttle position sensor with holes
in induction module. It may be necessary to turn the sen-
REMOVAL
sor slightly to align holes.
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
3.
Using a T20 TORX drive head, install two screws to
MAXI-FUSE, REMOVAL.
secure throttle position sensor to induction module.
Alternately tighten screws to 27-33 in-lbs (3.0-3.7 Nm).
2. Remove air cleaner and backplate. See Section 4.5 AIR
See Figure 9-32.
CLEANER, REMOVAL.
9-32
2004 Touring: Fuel Injection
HOME
4. Using the throttle lever mechanism, open and close the
throttle plates to check for proper operation. Be sure that
the mechanism operates smoothly without binding or
Throttle Cable
sticking.
Bracket
5. Install the throttle position sensor connector.
6. Install backplate and air cleaner. See Section 4.5 AIR
CLEANER, INSTALLATION.
7. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
MANIFOLD ABSOLUTE
PRESSURE SENSOR
T20 TORX
REMOVAL
Screws
8315
Figure 9-34. Remove Screws to Release Bracket
1WARNING
The screw securing the throttle cable bracket and idle air
f1701x9x
control flange to the induction module has a loctite
Electrical
patch that may make it very difficult to remove. Since a
Connector
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 pre-
cautions could result in death or serious injury.
1. See INDUCTION MODULE, REMOVAL, in this section.
CAUTION
Pressure Port
Rubber
Seal
The idle air control screw has a loctite patch that may
make it very difficult to remove. If necessary, use a heat
Figure 9-35. Manifold Absolute Pressure Sensor
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.
3.
Align hole in throttle cable bracket with hole at side of
2. Using a T20 TORX drive head, remove two screws to
induction module. Start screw into induction module.
release throttle cable bracket from induction module.
See Figure 9-34.
See Figure 9-34. Discard idle air control flange screw.
3. Pull pressure port from hole in induction module. See
4.
Align hole at top of throttle cable bracket with thru hole in
Figure 9-35.
flange of idle air control. Start new screw with loctite
patch into induction module.
5.
Using a T20 TORX drive head, tighten screw at side of
INSTALLATION
throttle cable bracket to 27-33 in-lbs (3.0-3.7 Nm).
1.
If reusing sensor, inspect rubber seal on pressure port
6.
Tighten flange screw of idle air control to 25 in-lbs (2.8
for cuts, tears or signs of deterioration. Replace as nec-
Nm).
essary. See Figure 9-35.
7.
Move free end of throttle return spring into slot in throttle
2.
With the electrical connector facing toward the rear of
cable bracket. See Figure 9-34.
the induction module
(side opposite throttle cable
bracket), insert pressure port into hole in induction mod-
8.
See INDUCTION MODULE, INSTALLATION, in this sec-
ule.
tion.
2004 Touring: Fuel Injection
9-33
HOME
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.
2.
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.
3.
Remove remaining screw to release flange of idle air
control from top of induction module. Discard screw.
4.
Pull idle air control from bore of induction module.
O-Ring
5.
Remove O-ring from body of idle air control. Discard O-
ring. See Figure 9-37.
Figure 9-37. Idle Air Control
INSTALLATION
7.
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
8.
Move free end of throttle return spring into slot in throttle
induction module (intake manifold side), install idle air
cable bracket.
control into bore.
9.
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
2004 Touring: Fuel Injection
HOME
1.
Throttle Position Sensor
21.
Adapter Seal (2)
2.
T20 TORX Screw- 14mm (3)
22.
Intake Manifold
11
3.
T10 TORX Screw (2)
23.
O-Ring
4.
Intake Air Temperature Sensor
24.
Throttle Body
13
5.
Gasket
6.
O-Ring
7.
Idle Air Control
14
10
8.
T20 TORX/Hex Screw (2)
11
9.
Throttle Cable Bracket
10.
Fuel Injector
15
11.
T20 TORX Screw- 17mm (5)
12.
Fuel Rail
16
13.
Fuel Supply Tube Clamp
8
14.
Fuel Supply Tube
15.
Sealing Washer
10
16.
O-Ring
7
12
17.
Manifold Absolute
Pressure Sensor
9
18.
Rubber Seal
19.
Socket Head Screw (4)
2
20.
Flange Adapter (2)
17
3
6
4
2
18
5
19
20
22
1
23
11
19
21
24
f2161x9x
Figure 9-38. Induction Module Assembly
2004 Touring: Fuel Injection
9-35
HOME
NOTES
9-36
2004 Touring: Fuel Injection
HOME
MAINTENANCE SCHEDULE
1.1
Table 1-1. Scheduled Maintenance Table
1
1
2
2
3
3
4
4
5
1
5
0
5
0
5
0
5
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
mi
Service
Service
Operation
Data
1
2
3
4
4
5
6
7
8
1
8
6
4
2
0
8
6
4
2
0
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
km
km
km
km
km
km
km
km
km
km
km
Check condition and
Battery
I
I
I
I
I
I
I
I
I
I
I
clean connections.
Oil level
Separate HOT and
COLD checks per
procedure.
Engine Oil
R
R
R
R
R
R
R
R
R
R
R
Oil capacity
4 qt. (3.8 L) per
chart in procedure.
Hand tighten
Engine
R
R
R
R
R
R
R
R
R
R
R
1/2-3/4 turn after
Oil Filter
gasket contact.
Deflection
Cold: 5/8-7/8 in.
Primary Chain
I
I
I
I
I
I
I
I
I
I
I
(15.9-22.2 mm)
Tension
Hot: 3/8-5/8 in. (9.5-
15.9 mm)
Lubricant capacity
32 oz (946 mL) Part
Primary Chain
R
R
R
R
R
R
R
R
R
R
R
No.’s
Lubricant
99887-84 (qt)
99886-84 (gal)
Free play at adjuster
screw
1/2-1 turn
Clutch
XL
XL
XL
XL
XL
XL
XL
XL
XL
XL
XL
Free play at hand
Adjustment
lever
1/16-1/8 in.
(1.6-3.2 mm)
R - Replace or change
I - Inspect (adjust, clean or replace as required)
L - Lubricate (with specified lubricant)
X - Perform
T - Tighten to proper torque
D - Disassemble (lube and inspect as required)
2004 FLT Police: Maintenance
1-1
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст