Harley Davidson FLHRC 2006. Maintenance & Repair Manual — page 31

HOME

Locate quick-connect fitting on left side of fuel tank. Pull

CONSOLE POD/CANOPY

up on chrome sleeve and insert neck of fuel supply line

fitting. While pushing up on bottom of fitting, pull down

on chrome sleeve until it “clicks” into the locked position.

FLHXI, FLHT/C/U/I, FLTRI

1WARNING

REMOVAL

To avoid an uncontrolled discharge or spray of gasoline,

always be sure the quick-connect fitting is properly

1WARNING

mated. A slight tug on the fuel supply line fitting will ver-

Gasoline will drain from the crossover hose when dis-

ify this condition. Gasoline is extremely flammable and

connected from the fuel tank. Thoroughly wipe up any

highly explosive. Inadequate safety precautions could

spilled fuel immediately. Dispose of rags in a suitable

result in death or serious injury.

manner. Gasoline is extremely flammable and highly

explosive. Inadequate safety precautions could result in

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

death or serious injury.

Slide head of console mounting bolt into slot at top of

canopy.

CAUTION

Moving instrument console toward installed position,

Do not kink crossover hose or crimp shut using pliers or

install fuel level sender/fuel pump connector [141], 4-

similar tool. Damage to the rigid inner lining will occur.

place Packard, at top of canopy. Bend flexible clamp to

capture main harness conduit.

Drain fuel tank as follows:

Exercising caution to avoid pinching harness and vent

Obtain a short section of hose with a 5/16 inch (7.9 mm)

tube, align hole in instrument console with console

I.D. Insert bolt in one end of hose and install hose clamp

mounting bolt and place into position on fuel tank. See

to ensure that end is securely plugged. Cut clamp from

Figure 9-13.

one end of crossover hose beneath fuel tank. Quickly

replace crossover hose on fuel tank fitting with open end

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

of short hose while directing flow of gasoline from free

frame backbone. On FLHRSI models, capture instru-

end of crossover hose into suitable container.

ment console bracket during installation. Tighten bolt to

15-20 ft-lbs (20-27 Nm).

Remove seat. See Section 2.25 SEAT, REMOVAL.

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

1WARNING

27 Nm).

The gasoline in the fuel supply line downstream of the

10.

Install acorn nut at top of instrument console and tighten

fuel pump is under high pressure (58 psi). To avoid an

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

uncontrolled discharge or spray of gasoline, always

lips screw and large flat washer (absent on FLHRSI

purge the system of high pressure gas before the fuel

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

supply line is disconnected. Inadequate safety precau-

11.

Connect fuel gauge to main harness. Route pin housing

tions could result in death or serious injury.

and convoluted tubing forward and then inboard

Purge the fuel supply line of high pressure gas. Proceed

between front of crossover hose fitting and bottom of fuel

as follows:

tank. Mate pin and socket halves of fuel gauge connec-

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

a. Remove the 15 amp fuel pump fuse. See Figure 9-

of fuel tank. See Figure 9-14.

10. If necessary, see Section

9.2 ELECTRICAL

BRACKET ASSEMBLY, EFI SYSTEM RELAY/EFI

12.

Insert bolt through battery negative cable (black) into

FUSES, REMOVAL.

threaded hole of battery negative (-) terminal. Tighten

b. Start the engine and allow the motorcycle to run.

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

c. When the engine stalls, operate starter for 3 sec-

13.

Install the 15 amp fuel pump fuse. See Figure 9-10. If

onds to remove remaining fuel from fuel lines.

necessary, see Section 9.2 ELECTRICAL BRACKET

ASSEMBLY, EFI SYSTEM RELAY/EFI FUSES, INSTAL-

LATION.

1WARNING

14.

Install seat. See Section 2.25 SEAT, INSTALLATION.

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.

2006 Touring: Fuel Injection

9-15

HOME

A spring-loaded hinge on the fuel pump bracket facili-

f1955x9x

tates removal of the assembly. For best results, press

down on top of fuel pump with index finger or end of

screwdriver, and after raising canopy slightly, rotate on

hinge in a counterclockwise direction. When canopy is at

a 45˚ angle to top of fuel tank, carefully pull assembly

from left side lobe of fuel tank. See Figure 9-17.

14. Remove and discard canopy gasket. Verify that sealing

devices from screws are not lodged in canopy holes.

Remove and discard devices if present.

INSTALLATION

Obtain new canopy gasket. With the locator bump on the

gasket OD toward the front, position gasket at bottom of

Convoluted

canopy. Start four nubs on gasket into holes in canopy.

Tube

Moving to top of canopy, alternately grasp each nub and

pull through hole.

Figure 9-15. Raise Canopy and Remove Tube

CAUTION

(FLHXI, FLHT/C/U/I, FLTRI)

Exercise care to avoid bending float rod of fuel level

sender during installation. Be sure to position float rod

Unthread bolt and remove battery negative cable (black)

to the right of the fuel gauge drain tube or it will be bent

from battery negative (-) terminal.

during installation of the canopy. A bent float rod will

result in erroneous gauge readings.

Open fuel door on console. Remove two Allen head

screws inboard of rubber bumpers. These screws secure

While holding fuel pump stationary, raise canopy slightly

console to clip nuts on the canopy bracket. If present,

and rotate on hinge 90˚ in a counterclockwise direction.

also remove Allen head screw to detach flange at rear of

Holding assembly so that canopy is at a 45˚ angle to top

console from clip nut on fuel tank weldment (absent on

of fuel tank, insert assembly into left side lobe of fuel

FLHXI models).

tank. The spring-loaded hinge on the fuel pump bracket

On FLHXI models only, remove bolt (with flat washer) to

automatically returns assembly to its installed position

free rear of fuel tank from frame backbone. Removal of

inside fuel tank.

rear bolt also releases console bracket.

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

CAUTION

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

Carefully inspect end of convoluted tube for cuts, tears,

sole and lay upside down on shop towel. Reinstall filler

holes or other damage. Replace tube if any damage is

cap.

found. Even the smallest hole can cause a reduction in

fuel pressure.

Remove fuel level sender/fuel pump connector [141], 4-

place Packard, at top of canopy.

Raise canopy slightly and slide new hose clamp onto

free end of convoluted tube. Install tube onto top fitting

10.

Gently pry fuel vapor vent tube from fitting on filler neck

(inlet port) at back of fuel pressure regulator. Crimp

of fuel tank. Exercise caution to avoid pulling fitting from

clamp. See Figure 9-15.

filler neck.

11.

Using a T20 TORX bit, remove ten screws around the

1WARNING

outer edge of the canopy. Discard screws.

Always use new screws when installing the canopy.

12.

Raise canopy slightly to access top fitting (inlet port) at

Reusing old screws may compromise sealing integrity

back of fuel pressure regulator. Using a side cutters, cut

resulting in gas leaks. Gas leakage can cause fire or

hose clamp and remove convoluted tube. Exercise cau-

explosion which could result in death or serious injury.

tion to avoid cutting or damaging tube or dropping

pieces of cut clamp into fuel tank. See Figure 9-15.

NOTE

13.

Remove canopy from fuel tank (with attached fuel pres-

Check canopy screws for proper sealing devices. Screws

sure regulator, fuel filter canister, fuel pump and fuel

must have a bonded seal on underside of head. Replace

level sender).

screws if seal is missing or damaged. See Figure 9-16.

9-16

2006 Touring: Fuel Injection

HOME

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

Sealing

threaded hole of battery negative (-) terminal. Tighten

Device

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

13. Install the 15 amp fuel pump fuse. See Figure 9-10. If

necessary, see Section 9.2 ELECTRICAL BRACKET

ASSEMBLY, EFI SYSTEM RELAY/EFI FUSES, INSTAL-

LATION.

f1963x9x

14. Install seat. See Section 2.25 SEAT, INSTALLATION.

f1957x9x

f2011x9x

Figure 9-16. Canopy Sealing Screws and Torque

Sequence

While pushing down on the canopy, align holes in can-

opy with those in fuel tank. Hand start ten new T20

f1956x9x

TORX screws in perimeter of canopy. Tighten screws to

18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in

Figure 9-16.

Connect fuel vapor vent tube to fitting on filler neck of

fuel tank.

Install fuel level sender/fuel pump connector [141], 4-

place Packard, at top of canopy.

Remove filler cap. Exercising caution to avoid pinching

harnesses, overflow hose and vent tube, position con-

sole on canopy as shown in Figure 9-12. Reinstall filler

cap.

Open fuel door on console. Install two Allen head screws

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

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

present, also install Allen head screw to fasten rear

flange of console to clip nut on fuel tank weldment

(absent on FLHXI models). Tighten screw to 25-30 in-lbs

Figure 9-17. Remove Canopy From Motorcycle

(2.8-3.4 Nm).

(FLHR/C/S/I)

10.

On FLHXI models only, install bolt (with flat washer) to

secure rear of fuel tank and console bracket to frame

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

11.

Slide new clamp onto free end of crossover hose. Install

hose onto fitting at bottom of fuel tank. Crimp clamp

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

2006 Touring: Fuel Injection

9-17

HOME

Remove acorn nut from instrument console. If present,

INSTRUMENT CONSOLE/CANOPY

also remove Phillips screw and large flat washer (absent

on FLHRSI models).

FLHR/C/S/I

On FLHRSI models only, remove bolt (with flat washer)

to free rear of fuel tank from frame backbone. Removal

REMOVAL

of rear bolt also releases instrument console bracket.

Raise instrument console and bend back flexible clamp

1WARNING

on canopy to release main harness conduit. Remove

Gasoline will drain from the crossover hose when dis-

fuel level sender/fuel pump connector

[141],

4-place

connected from the fuel tank. Thoroughly wipe up any

Packard, at top of canopy.

spilled fuel immediately. Dispose of rags in a suitable

manner. Gasoline is extremely flammable and highly

CAUTION

explosive. Inadequate safety precautions could result in

death or serious injury.

When removing instrument console, exercise caution to

avoid damaging speedometer unit. Wrap console in a

clean, dry shop towel to prevent damage.

CAUTION

Do not kink crossover hose or crimp shut using pliers or

Secure instrument console to top of rear fender using

similar tool. Damage to the rigid inner lining will occur.

bungee cords.

Drain fuel tank as follows:

Remove console mounting bolt from slot at top of can-

Obtain a short section of hose with a 5/16 inch (7.9 mm)

opy.

I.D. Insert bolt in one end of hose and install hose clamp

10.

Gently pry fuel vapor vent tube from fitting 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.

Using a T20 TORX bit, remove ten screws around the

of short hose while directing flow of gasoline from free

outer edge of the canopy. Discard screws.

end of crossover hose into suitable container.

Remove seat. See Section 2.25 SEAT, REMOVAL.

12.

Raise canopy slightly to access top fitting (inlet port) at

back of fuel pressure regulator. Using a side cutters, cut

hose clamp and remove convoluted tube. Exercise cau-

1WARNING

tion to avoid cutting or damaging tube or dropping

The gasoline in the fuel supply line downstream of the

pieces of cut clamp into fuel tank. See Figure 9-15.

fuel pump is under high pressure (58 psi). To avoid an

13.

Remove canopy from fuel tank (with attached fuel pres-

uncontrolled discharge or spray of gasoline, always

sure regulator, fuel filter canister, fuel pump and fuel

purge the system of high pressure gas before the fuel

level sender).

supply line is disconnected. Inadequate safety precau-

tions could result in death or serious injury.

A spring-loaded hinge on the fuel pump bracket facili-

Purge the fuel supply line of high pressure gas. Proceed

tates removal of the assembly. For best results, press

down on top of fuel pump with index finger or end of

as follows:

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 SYSTEM RELAY/EFI

from left side lobe of fuel tank. See Figure 9-17.

FUSES, REMOVAL.

b. Start the engine and allow the motorcycle to run.

14.

Remove and discard canopy gasket. Verify that sealing

devices from screws are not lodged in canopy holes.

c. When the engine stalls, operate starter for 3 sec-

Remove and discard devices if present.

onds to remove remaining fuel from fuel lines.

1WARNING

INSTALLATION

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

cle, disconnect the negative battery cable before pro-

Obtain new canopy gasket. With the locator bump on the

ceeding. Inadequate safety precautions could result in

gasket OD toward the front, position gasket at bottom of

death or serious injury.

canopy. Start four nubs on gasket into holes in canopy.

Moving to top of canopy, alternately grasp each nub and

Unthread bolt and remove battery negative cable (black)

pull through hole.

from battery negative (-) terminal.

9-18

2006 Touring: Fuel Injection

HOME

10. Install acorn nut at top of instrument console and tighten

CAUTION

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

Phillips screw and large flat washer (absent on FLHRSI

Exercise care to avoid bending float rod of fuel level

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

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).

While holding fuel pump stationary, raise canopy slightly

12. Slide new clamp onto free end of crossover hose. Install

and rotate on hinge 90˚ in a counterclockwise direction.

hose onto fitting at bottom of fuel tank. Crimp clamp

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

Holding assembly so that canopy is at a 45˚ angle to top

of fuel tank, insert assembly into left side lobe of fuel

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

tank keeping the float rod positioned to the right of the

threaded hole of battery negative (-) terminal. Tighten

fuel gauge drain tube. The spring-loaded hinge on the

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

fuel pump bracket automatically returns assembly to its

14. Install the 15 amp fuel pump fuse. See Figure 9-10. If

installed position inside fuel tank.

necessary, see Section 9.2 ELECTRICAL BRACKET

ASSEMBLY, EFI SYSTEM RELAY/EFI FUSES, INSTAL-

LATION.

CAUTION

15. Install seat. See Section 2.25 SEAT, INSTALLATION.

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 FILTER CANISTER

fuel pressure.

Raise canopy slightly and slide new hose clamp onto

See Section

1.2 MAINTENANCE SCHEDULE for the

free end of convoluted tube. Install tube onto top fitting

required service interval, and then proceed as follows:

(inlet port) at back of fuel pressure regulator. Crimp

clamp. See Figure 9-15.

REMOVAL

1WARNING

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

FLTRI, REMOVAL, or INSTRUMENT CONSOLE/CAN-

Always use new screws when installing the canopy.

OPY, FLHR/C/S/I, REMOVAL.

Reusing old screws may compromise sealing integrity

Release fuel filter canister as follows:

resulting in gas leaks. Gas leakage can cause fire or

explosion which could result in death or serious injury.

a. Pull wireform to release from slots on fuel filter can-

ister bracket. See A of Figure 9-18.

NOTE

b. Use hinge to swing wireform out of the way. Move

Check canopy screws for proper sealing devices. Screws

canister bracket forward to disengage tab from slot

must have a bonded seal on underside of head. Replace

on canopy weldment. See B of Figure 9-18.

screws if seal is missing or damaged. See Figure 9-16.

c. Pull fitting on canister from fuel pressure regulator

assembly. See C of Figure 9-18.

While pushing down on the canopy, align holes in can-

opy with those in fuel tank. Hand start ten new T20

Using a side cutters, cut hose clamp and remove convo-

TORX screws in perimeter of canopy. Tighten screws to

luted tube from inlet port at side of fuel filter canister.

18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in

Exercise caution to avoid cutting or damaging tube. Dis-

Figure 9-16.

card fuel filter canister.

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

Slide head of console mounting bolt into slot at top of

INSTALLATION

canopy.

Moving instrument console toward installed position,

CAUTION

install fuel level sender/fuel pump connector [141], 4-

Do not replace tubes inside of fuel tank with ordinary

place Packard, at top of canopy. Bend flexible clamp to

capture main harness conduit.

bulk hose. All internal lines must be replaced with the

special original equipment convoluted nylon tubes. Bulk

Exercising caution to avoid pinching harness and vent

hose will degrade when immersed in gasoline (particu-

tube, align hole in instrument console with console

larly stale gasoline), resulting in contamination of the

mounting bolt and place into position on fuel tank. See

fuel supply. Use of contaminated fuel will cause starting

Figure 9-13.

and driveability problems and possible vehicle damage.

2006 Touring: Fuel Injection

9-19

HOME

If present, remove and discard plastic caps from fittings

of new fuel filter canister.

Slide new hose clamp onto free end of convoluted tube

(from fuel pump). Install tube onto inlet port at side of

fuel filter canister. If necessary, use a little isopropyl

alcohol or glass cleaner to aid installation. Crimp clamp.

Install fuel filter canister as follows:

a. Install new O-ring onto fitting of fuel filter canister.

Insert fitting into fuel pressure regulator assembly,

so that inlet port is on fuel pump side. See C of Fig-

ure 9-18.

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 9-18.

c. Use hinge to rotate wireform over canister bracket.

f1940x9x

Press on wireform until it fully engages slots on can-

ister bracket. See A of Figure 9-18.

d. Verify that socket terminal is firmly installed on

spade contact on canister bracket, if present.

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.

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

FLTRI, INSTALLATION, or INSTRUMENT CONSOLE/

CANOPY, FLHR/C/S/I, INSTALLATION.

FUEL PRESSURE REGULATOR

f1945x9x

REMOVAL

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

FLTRI, REMOVAL, or INSTRUMENT CONSOLE/CAN-

OPY, FLHR/C/S/I, REMOVAL.

See FUEL FILTER CANISTER, REMOVAL, step 2.

Slide fuel pressure regulator assembly forward to free

arms from catches on canopy weldment. See Figure 9-

19.

Remove fuel pressure regulator from housing. To over-

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 9-20.

Inspect O-rings for cuts, tears or general deterioration.

Replace the O-rings if they have taken a definite set.

INSTALLATION

f1944x9x

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

Install O-rings in grooves of fuel pressure regulator. See

Figure 9-20.

Figure 9-18. Remove Fuel Filter Canister (FLHR/C/S/I)

9-20

2006 Touring: Fuel Injection

HOME

Using a side cutters, cut hose clamp and pull convoluted

tube from fuel pump outlet port. Exercise caution to

avoid cutting or damaging tube (and cracking or break-

ing outlet port).

Remove T15 TORX screw and pull fuel level sender from

post on fuel pump bracket.

Release end of return spring from hook on fuel pump

bracket.

Remove fuel pump as follows:

NOTE

Two methods are presented based upon whether the fuel

pump is being discarded or retained. If the fuel pump is faulty,

follow step

6(a). Note that the hinge is damaged during

removal so replacement of the fuel pump and bracket assem-

f1943x9x

bly is required. On the other hand, if the fuel pump and

bracket assembly are still serviceable, follow step 6(b) to

Figure 9-19. Remove Fuel Pressure Regulator

remove without damaging.

(FLHR/C/S/I)

a. Insert flat tip screwdriver at location shown in Figure

9-21. Carefully crack plastic webbing at top of hinge

and remove from support arm. Discard fuel pump

and bracket assembly.

b. Using the tip of a needle nose pliers, depress pin

and slide hinge off end of support arm. See Figure

9-21.

Inspect the condition of the fuel pump wiring. If the wir-

Housing

ing needs to be replaced, see FUEL PUMP/FUEL

LEVEL SENDER WIRING on the next page.

O-Ring

f1931x9x

INSTALLATION

Figure 9-20. Fuel Pressure Regulator Assembly

If removed, install hinge at top of fuel pump bracket, so

that support arm slot is on the fuel level sender mount

Install fuel pressure regulator into housing.

side.

Fit fuel pressure regulator assembly into canopy weld-

ment engaging arms in catches. See Figure 9-19.

See FUEL FILTER CANISTER, INSTALLATION, step 3.

8399

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

Screwdriver

FLTRI, INSTALLATION, or INSTRUMENT CONSOLE/

CANOPY, FLHR/C/S/I, INSTALLATION.

FUEL PUMP

REMOVAL

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

FLTRI, REMOVAL, or INSTRUMENT CONSOLE/CAN-

Pin

OPY, FLHR/C/S/I, REMOVAL.

Depress external latch and remove electrical connector

Figure 9-21. Either Crack Webbing or Depress Pin

at top of fuel pump.

to Remove Hinge From Support Arm

2006 Touring: Fuel Injection

9-21

HOME

Slide end of support arm into slot at top of hinge. Pull on

Remove socket terminal from spade contact on either

hinge to verify that it is locked by pin on support arm.

connector clip or fuel filter canister bracket.

Install free end of return spring onto hook on fuel pump

bracket.

Depress external latch and remove electrical connector

at top of fuel pump.

CAUTION

Remove T15 TORX screw and pull fuel level sender from

post on fuel pump bracket.

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.

INSTALLATION

Slide new hose clamp onto free end of convoluted tube

Align two holes in fuel level sender with threaded hole

(to fuel filter canister inlet). Install tube onto outlet port of

and post on fuel pump bracket. Install T15 TORX screw

fuel pump. Crimp clamp, but exercise caution to avoid

in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).

cracking or breaking outlet port.

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.

Align two holes in fuel level sender with threaded hole

At bottom of canopy, install socket housing of 4-place

and post on fuel pump bracket. Install T15 TORX screw

Packard connector.

in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).

Install socket terminal onto spade contact on either con-

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

nector clip or fuel filter canister bracket.

FLTRI, INSTALLATION, or INSTRUMENT CONSOLE/

CANOPY, FLHR/C/S/I, INSTALLATION.

Install new cable strap to attach fuel pump/fuel level

sender wiring to support arm. Cut any excess cable

strap material.

FUEL PUMP/FUEL LEVEL SENDER

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

WIRING

FLTRI, INSTALLATION, or INSTRUMENT CONSOLE/

CANOPY, FLHR/C/S/I, INSTALLATION.

CAUTION

Do not replace the special teflon coated fuel pump/fuel

FUEL SUPPLY CHECK VALVE/TUBE

level sender wiring with ordinary bulk wire. Ordinary

insulation materials may deteriorate when in contact

with gasoline.

NOTE

The in-tank check valve is housed in the quick-connect fitting.

Damaged wiring, terminals and/or connectors requires

The check valve prevents the fuel tank from draining when

replacement of the fuel level sender unit. See FUEL LEVEL

the external supply line is disconnected.

SENDER on this page.

REMOVAL

FUEL LEVEL SENDER

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

FLTRI, REMOVAL, steps 1-12, or INSTRUMENT CON-

SOLE/CANOPY, FLHR/C/S/I, REMOVAL, steps 1-12.

REMOVAL

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

1WARNING

FLTRI, REMOVAL, or INSTRUMENT CONSOLE/CAN-

A small amount of gasoline may drain from the fuel sup-

OPY, FLHR/C/S/I, REMOVAL.

ply line when disconnected from the fuel tank. Thor-

Cut cable strap to release fuel pump/fuel level sender

oughly wipe up any spilled fuel immediately. Dispose of

wiring from support arm.

rags in a suitable manner. Gasoline is extremely flamma-

ble and highly explosive. Inadequate safety precautions

At bottom of canopy, depress external latch and remove

could result in death or serious injury.

socket housing of 4-place Packard connector.

9-22

2006 Touring: Fuel Injection

HOME

f2048x9x

Chrome Sleeve

Body Hex

O-Ring

Convoluted Tube

Figure 9-22. Fuel Supply Check Valve/Tube (Quick-Connect Fitting)

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

1WARNING

new O-ring. Slide O-ring down convoluted tube and into

groove of new quick-connect fitting. See Figure 9-22.

Exercise caution to avoid twisting the fuel supply line fit-

Feeding convoluted tube through hole at bottom of fuel

ting, as any cracks in the plastic construction of the line

tank, hand thread quick-connect fitting into bore. Look-

can result in gas leaks. Gas leakage can cause fire or

ing down at top of fuel tank, rotate fitting in a counter-

explosion which could result in death or serious injury.

clockwise direction until snug.

Locate quick-connect fitting on left side of fuel tank. Pull

Slide a 7/8 inch deepwell socket over chrome sleeve

up on chrome sleeve and pull down on fuel supply line

engaging hex on quick-connect fitting. Tighten fitting to

fitting to disconnect. See Figure 9-11.

22-26 ft-lbs (29.8-35.3 Nm).

1WARNING

A small amount of gasoline may drain from the fuel tank

Exercise caution to avoid twisting the fuel supply line fit-

when the quick-connect fitting is removed. Thoroughly

ting, as any cracks in the plastic construction of the line

wipe up any spilled fuel immediately. Dispose of rags in

can result in gas leaks. Gas leakage can cause fire or

a suitable manner. Inadequate safety precautions could

explosion which could result in death or serious injury.

result in death or serious injury.

Pull up on chrome sleeve of quick-connect fitting and

Slide a 7/8 inch deepwell socket over chrome sleeve

insert neck of fuel supply line fitting. While pushing up on

engaging hex on quick-connect fitting. See Figure 9-22.

bottom of fitting, pull down on chrome sleeve until it

Looking down at top of fuel tank, rotate fitting in a clock-

“clicks” into the locked position.

wise direction until it turns easily. Remove the fitting by

hand drawing convoluted tube out through hole at bot-

1WARNING

tom of fuel tank.

To avoid an uncontrolled discharge or spray of gasoline,

always be sure the quick-connect fitting is properly

INSTALLATION

mated. A slight tug on the fuel supply line fitting will ver-

ify this condition. Gasoline is extremely flammable and

highly explosive. Inadequate safety precautions could

CAUTION

result in death or serious injury.

Carefully inspect convoluted tube for cuts, tears, holes

See CONSOLE POD/CANOPY, FLHXI, FLHT/C/U/I,

or other damage. Replace tube (with attached quick-con-

FLTRI, INSTALLATION, steps 4-14, or INSTRUMENT

nect fitting) if any damage is found. Even the smallest

CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION,

hole can cause a reduction in fuel pressure.

steps 4-15.

2006 Touring: Fuel Injection

9-23

HOME

NOTES

9-24

2006 Touring: Fuel Injection

HOME

INDUCTION MODULE ASSEMBLY

9.5

On cruise control equipped models, remove E-clip from

INDUCTION MODULE

sleeve at end of cruise cable housing. Using slot,

remove cable housing from cable guide in throttle cable

bracket. Push the plastic end fitting on the cruise cable

REMOVAL

to the outboard side to release from wheel pin. See Fig-

ure 9-24.

Partially remove fuel tank. See Section 9.4 FUEL TANK

Remove IAC connector [87] and MAP sensor connector

(FUEL INJECTED), PARTIAL REMOVAL, either FLHXI,

FLHT/C/U/I, FLTRI or FLHR/C/S/I.

[80].

Remove front fuel injector connector [84] and rear fuel

Remove air cleaner and backplate. See Section 4.5 AIR

injector connector [85].

CLEANER, REMOVAL.

Remove TP sensor connector [88] and IAT sensor con-

Pull purge tube from fitting at top of induction module

nector [89].

(California models only). See Figure 9-23.

Remove right side allen head socket screws from front

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

and rear cylinder head flange adapters. For best results,

rel from upper hole in throttle wheel. Pull throttle cable

use the INTAKE MANIFOLD WRENCH (HD-47250), or a

barrel from lower hole. Using slots, release idle and

long 1/4 inch ball allen head socket with end driver 4

throttle cables from guides in throttle cable bracket.

inches long.

f2363x9x

Front

Rear

Front Fuel Injector [84]

TP Sensor [88]

MAP Sensor [80]

Throttle Cable/IAC Bracket

Purge Tube Fitting/Rubber Cap

Rear Fuel Injector [85]

Throttle Wheel

(Used on California Models Only)

10. Fuel Rail

IAC [87]

IAT Sensor [89]

11. Fuel Supply Tube

Figure 9-23. Induction Module Assembly

2006 Touring: Fuel Injection

9-25

HOME

Place a new seal in each flange adapter with the bev-

eled side in against the counterbore.

f2374x9x

Standing on right side of engine, slide induction module

toward installed position so that open-ended slots on

flange adapters begin to engage allen head socket

screws loosely installed on left side. Use caution around

horn bracket to prevent damage to fuel supply line.

Install sleeve on throttle cable housing into cable guide

at top of throttle cable bracket. Drawing throttle cable

downward, fit barrel end into lower hole in throttle wheel.

Install sleeve and spring on idle cable housing into cable

guide at bottom of throttle cable bracket inserting barrel

end into upper hole in throttle wheel.

On cruise control equipped models, slide groove in

cruise cable end fitting over cap of wheel pin. Push on

Figure 9-24. Remove End Fitting From Wheel Pin

end fitting until it snaps in place. Using slot, slip cruise

cable housing into cable guide in throttle cable bracket.

At bottom of bracket, install new E-clip on sleeve at end

10. Moving to opposite side of motorcycle, just loosen left

of cruise cable housing.

side allen head socket screws from flange adapters.

Slots in flanges make removal of left side screws unnec-

Align fixed holes in flange adapters with those in cylinder

essary. To better access bolts, loosen acorn nut and

heads and start allen head socket screws. For best

swing horn assembly out of the way.

results, use the INTAKE MANIFOLD WRENCH (HD-

11. Slide induction module out from right side of motorcycle.

47250), or a long 1/4 inch ball allen head socket with

Use caution around horn bracket to prevent damage to

end driver 4 inches long.

fuel supply line.

Use the air cleaner backplate to properly locate induc-

tion module. Install two breather bolts to fasten back-

1WARNING

plate to front and rear cylinder heads. Install three T27

TORX screws to secure backplate to face of induction

A small amount of gasoline will drain from the fuel sup-

module. See Figure 9-26.

ply line when disconnected from the fuel supply tube.

Thoroughly wipe up any spilled fuel immediately. Dis-

Tighten allen head socket screw in fixed holes of flange

pose of rags in a suitable manner. Gasoline is extremely

adapters until snug. Moving to left side of engine, tighten

flammable and highly explosive. Inadequate safety pre-

screws in slotted holes to 96-144 in-lbs (10.9-16.3 Nm).

cautions could result in death or serious injury.

If moved, swing horn assembly back into position and

12. Depress button on fuel supply line and remove from fuel

tighten acorn nut.

supply tube. See Figure 9-25.

13. Remove seals from flange adapters. Discard seals.

Remove flange adapters from outlet ports of induction

f2373x9x

module.

Button

INSTALLATION

Slide fuel supply line onto fuel supply tube of induction

module. A slight tug will verify that the line is locked in

place.

Orientate the induction module as shown in Figure 9-23.

With the counterbore facing outward, slide cylinder head

flange adapters onto outlet ports of induction module.

The flange adapters are not interchangeable. Look next

to the slotted bolt hole for a stamp that indicates F(ront)

Figure 9-25. Remove Fuel Supply Line From Supply Tube

and R(ear) cylinder.

9-26

2006 Touring: Fuel Injection

HOME

FUEL SUPPLY TUBE/FUEL RAIL/

Breather Bolts

f1966x9x

FUEL INJECTORS

REMOVAL

Remove induction module. See INDUCTION MODULE,

REMOVAL.

Remove hex screw (with pilot sleeve) to release fuel

supply tube clamp. See Figure 9-27.

Pull fuel supply tube from fuel rail. Remove sealing

washer and O-ring from fuel supply tube. Remove sec-

ond O-ring from fuel rail bore. Discard sealing washer

and O-rings. See Figure 9-28.

Pull fuel injectors with attached fuel rail from induction

module. To overcome the resistance of the bottom O-

ring on both fuel injectors, gently rock assembly back

T27 TORX

and forth while pulling.

Screws

Remove spring clips from fuel injectors. Pull fuel injec-

tors from fuel rail. To overcome the resistance of the top

Figure 9-26. Install Backplate to Align Induction Module

O-ring, gently rock each fuel injector while pulling.

10.

Remove breather bolts and T27 TORX screws to remove

backplate.

11.

Tighten allen head socket screws in fixed holes of flange

adapters to 96-144 in-lbs (10.9-16.3 Nm).

12.

Install rear fuel injector connector

[85] and front fuel

injector connector [84].

13.

Install MAP sensor connector [80] and IAC connector

[87].

14.

Install IAT sensor connector [89] and TP sensor connec-

tor [88].

9460

15.

Connect purge tube to fitting at top of induction module

(California models only).

Figure 9-27. Fuel Supply Tube Clamp Hex Screw

On non-California models, inspect rubber cap for tears,

cracks or signs of deterioration. Replace cap if damaged

or missing. Figure

9-23. Operation without cap can

f2368x9x

result in engine damage.

16.

Install fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION

(AFTER PARTIAL

REMOVAL), FLHXI, FLHT/C/U/I, FLTRI or FLHR/C/S/I.

17.

Turn the Ignition/Light Key Switch to ON and then back

to OFF to reset IAC to park position.

18.

Install backplate and air cleaner. See Section 4.5 AIR

Hex Screw/Pilot Sleeve

CLEANER, INSTALLATION.

Fuel Supply Tube

O-Ring (2)

19.

Check throttle and idle cable adjustment. Check cruise

Sealing Washer

cable adjustment.

Figure 9-28. Fuel Supply Tube Assembly

2006 Touring: Fuel Injection

9-27

HOME

Push fuel supply tube into fuel rail bore until clamp is

f2365x9x

seated on round step of fuel rail. Install hex screw (with

O-Ring

pilot sleeve) and tighten to

90-110 in-lbs (10.2-12.4

Nm). See Figure 9-27.

Install induction module. See INDUCTION MODULE,

INSTALLATION.

Spring Clip

IAT SENSOR

Figure 9-29. Fuel Injector Assembly

REMOVAL

Fork

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

Injector Tab

MAXI-FUSE, REMOVAL.

Opening

Lip

Remove air cleaner and backplate. See Section 4.5 AIR

Rail Tab

CLEANER, REMOVAL.

Remove IAT sensor connector [89].

Remove T20 TORX screw (with captive washer) to

release IAT sensor from induction module. Discard

screw. See Figure 9-23.

9470

INSTALLATION

Figure 9-30. Install Spring Clips

Inspect O-ring in groove of IAT sensor for cuts, tears or

signs of deterioration. Install new O-ring if necessary.

Remove O-rings from fuel injectors. Discard O-rings.

See Figure 9-31.

See Figure 9-29.

Insert sensor into induction module with electrical con-

nector facing toward the left side of the motorcycle. See

INSTALLATION

Figure 9-23.

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

Install new T20 TORX screw (with captive washer) to

Install O-rings on fuel injectors, the thicker O-ring with

fasten IAT sensor to induction module. Tighten screw to

the smaller ID going on the fuel rail (high pressure) side.

15-20 in-lbs (1.7-2.3 Nm).

See Figure 9-29.

Install IAT sensor connector [89].

Push electrical connector side of fuel injectors into fuel

rail.

With the concave side toward the fuel rail, install spring

clip into slot on fuel injector. In the installed position,

f2366x9x

Thermistor

openings in sides of clip engage lip on fuel rail, while fork

at back of clip captures tab on fuel injector. See Figure

O-Ring

9-30.

Rotate fuel injectors, so that the electrical connectors

are on the outboard side. Push fuel injectors into induc-

tion module bores until tab on fuel rail engages

machined slot at top of induction module.

Slide new O-ring down shorter neck of the fuel supply

tube until it contacts the collar. Slide new sealing washer

down tube until it contacts O-ring. Install second O-ring

Figure 9-31. IAT Sensor

in fuel rail bore. See Figure 9-28.

9-28

2006 Touring: Fuel Injection

HOME

Install backplate and air cleaner. See Section 4.5 AIR

CLEANER, INSTALLATION.

Throttle Cable/

IAC Bracket

IAC

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

TP SENSOR

REMOVAL

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

Remove air cleaner and backplate. See Section 4.5 AIR

CLEANER, REMOVAL.

9471

Remove TP sensor connector [88].

Figure 9-33. Remove Screws to Release Bracket

Remove two T20 TORX screws (with captive washers) to

release TP sensor from induction module. Discard

screws. See Figure 9-23.

f1701x9x

INSTALLATION

Inspect O-ring in groove of TP sensor for cuts, tears or

signs of deterioration. Install new O-ring if necessary.

See Figure 9-32.

Fit pocket of TP sensor over throttle shaft engaging

Pressure Port

Rubber

index pin with hole on machined flange of induction

Seal

module.

Install two new T20 TORX screws (with captive washers)

Figure 9-34. MAP Sensor

to fasten TP sensor to induction module. Alternately

tighten screws to 15-20 in-lbs (1.7-2.3 Nm). See Figure

9-23.

Install TP sensor connector [88].

Using the throttle lever mechanism, open and close the

Install backplate and air cleaner. See Section 4.5 AIR

throttle plates to check for proper operation. Be sure that

CLEANER, INSTALLATION.

the mechanism operates smoothly without binding or

sticking.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

9472

MAP SENSOR

Index Pin

REMOVAL

Remove induction module. See INDUCTION MODULE,

REMOVAL.

Remove two T20 TORX screws to release throttle cable/

IAC bracket from induction module. Discard screws. See

O-Ring

Figure 9-33.

Pull pressure port on MAP sensor from hole in induction

Figure 9-32.

TP Sensor

module. See Figure 9-34.

2006 Touring: Fuel Injection

9-29

HOME

Induction Module

16. Sealing Washer

24. Adapter Seal (2)

Rubber Cap

17. Fuel Rail

25. Flange Adapter (2)

T20 TORX Screw (2)

18. Spring Clip (2)

26. Socket Head Screw (4)

TP Sensor

19. Fuel Injector (2)

O-Ring

20. O-Ring, High Pressure (2)

T20 TORX Screw

21. O-Ring, Low Pressure (2)

IAT Sensor

22. MAP Sensor

O-Ring

23. Rubber Seal

T20 TORX (2)

10. IAC

11. O-Ring

12. Throttle Cable/IAC Bracket

13. Hex Screw/Pilot Sleeve

14. Fuel Supply Tube/Clamp

15. O-Ring (2)

f2426x9x

Figure 9-35. Induction Module Assembly

INSTALLATION

Insert index pin at bottom of throttle cable/IAC bracket

into hole in boss at top of induction module. See Figure

Inspect rubber seal on pressure port for cuts, tears or

9-36.

signs of deterioration. Install new rubber seal if neces-

sary. See Figure 9-34.

Align holes in throttle cable/IAC bracket with thru holes

in flange of IAC. See Figure 9-33.

With the electrical connector facing toward the rear of

the induction module

(side opposite throttle wheel),

Install two new T20 TORX screws and alternately tighten

insert pressure port on MAP sensor into hole in induc-

to 20-35 in-lbs (2.3-4.0 Nm). See Figure 9-33.

tion module.

9-30

2006 Touring: Fuel Injection

HOME

Install induction module. See INDUCTION MODULE,

INSTALLATION.

Index Pin

IAC

REMOVAL

Remove induction module. See INDUCTION MODULE,

REMOVAL.

f2370x9x

Remove two T20 TORX screws to release throttle cable/

IAC bracket from induction module. Discard screws. See

Figure 9-36. Throttle Cable/IAC Bracket

Figure 9-33.

Pull IAC from bore of induction module. Remove O-ring

f2367x9x

from counterbore. Discard O-ring. See Figure 9-37.

INSTALLATION

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

O-Ring

Install O-ring in counterbore of induction module.

With the electrical connector facing the rear left side of

the induction module, install IAC into bore.

Insert index pin at bottom of throttle cable/IAC bracket

into hole in boss at top of induction module. See Figure

9-36.

Figure 9-37. IAC

Align holes in throttle cable/IAC bracket with thru holes

in flange of IAC.

Install two new T20 TORX screws and alternately tighten

to 20-35 in-lbs (2.3-4.0 Nm). See Figure 9-33.

Install induction module. See INDUCTION MODULE,

INSTALLATION.

2006 Touring: Fuel Injection

9-31

HOME

DEUTSCH ELECTRICAL CONNECTORS

B.1

GENERAL

f1049a8x

Attachment clips are attached to the pin housings of some

connectors. The clips are then attached to T-studs on the

motorcycle frame. T-studs give positive location to electrical

connectors and wire harnesses. Consistent location reduces

electrical problems and improves serviceability.

To become familiar with the Deutsch connector, read the

parts description below while referencing the 12-place con-

nector illustrated in Figure B-3.

Socket housing: alignment tabs and/or external latch, sec-

ondary locking wedge, internal seal, wire seal, seal pin.

NOTE

Figure B-2. Depress Terminal Latches/Back Out Pins

Seal pins or plugs are installed in the wire seals of unused

chambers. If removed, seal pins must be replaced to main-

NOTE

tain the integrity of the environmental seal.

With few exceptions, the socket housing can always be found

Pin housing: alignment grooves and/or external latch cover,

on the accessory side, while the pin side of the connector is

secondary locking wedge, wire seal, seal pin.

plumbed to the wiring harness.

REMOVING/DISASSEMBLING

REMOVING/INSTALLING SOCKETS

Push the connector to disengage small end of slot on

attachment clip fromT-stud. Lift connector off T-stud.

See Figure B-1. Remove the secondary locking wedge.

Depress the external latch(es) on the socket housing

Insert the blade of a small screwdriver between the

side and use a rocking motion to separate the pin and

socket housing and locking wedge inline with the groove

socket halves. Two-, three-, four- and six-place Deutsch

(inline with the pin holes if the groove is absent). Turn the

connectors have one external latch, while eight- and

screwdriver 90 degrees to pop the wedge up.

twelve-place connectors have two, both of which must

be pressed simultaneously to separate the connector

Gently depress terminal latches inside socket housing

and back out sockets through holes in rear wire seal.

halves.

See Figure B-2.

NOTE

4566

If new terminals must be installed, see CRIMPING

INSTRUCTIONS in this section.

Fit rear wire seal into back of socket housing, if removed.

Grasp socket approximately 1 inch (25.4 mm) behind the

contact barrel. Gently push sockets through holes in wire

seal into their respective chambers. Feed socket into

chamber until it “clicks” in place. Verify that socket will

not back out of chamber; a slight tug on the wire will con-

firm that it

Install internal seal on lip of socket housing, if removed.

Insert tapered end of secondary locking wedge into

socket housing and press down until it snaps in place.

The wedge fits into the center groove within the socket

housing and holds the terminal latches tightly closed.

Figure B-1. Remove Secondary Locking Wedge

Appendix B B-1

HOME

f1915x8x

Wire Seal

Pin

Housing

Pin

Terminal

Locking Wedge

(Pin Side)

Locking Wedge

(Socket Side)

Internal

Seal

Latch Cover

Socket

Housing

Alignment

Grooves

Wire

Seal

Alignment

Tabs

Seal

NOTE

Pin

For exploded views of 2-place,

3-place and

4-place Deutsch

connectors, see Figure B-5.

External

Latch

Socket

Terminal

Figure B-3. 12-Place Deutsch Connector (Exploded View)

NOTE

While rectangular wedges do not require a special orienta-

tion, the conical secondary locking wedge of the 3-place con-

nector must be installed with the arrow pointing toward the

Pin

external latch. See Figure B-4.

Housing

NOTE

If the secondary locking wedge does not slide into the

Arrow Points to

installed position easily, verify that all terminals are fully

External Latch

installed in the socket housing. The lock indicates when ter-

minals are not properly installed by not entering its fully

installed position.

Socket

Housing

REMOVING/INSTALLING PINS

Remove the secondary locking wedge. Use the hooked

f1515x8x

end of a stiff piece of mechanics wire, a needle nose pli-

ers or a suitable pick tool (HD-41475-100). See Figure

B-6.

Figure B-4. 3-Place Locking Wedge Orientation

B-2

Appendix B

HOME

f1510x8x

2-Place Connector

3-Place Connector

4-Place Connector

Socket Side

Pin Side

Socket Terminal

Locking Wedge

Wire Seal

Latch Cover

Socket Housing

Pin Housing

External Latch

10. Wire Seal

Internal Seal

11. Pin Terminal

Locking Wedge

Figure B-5. 2-Place, 3-Place and 4-Place Deutsch Connectors

Appendix B B-3

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