| | | ------------------------------------------------------------------------------------------------------------------------------------------------------------- 280 CHAPTER SEVEN 28 29 dle extending out of the bottom of the vacuum pis- ton. 30 6. Remove the float bowl as follows: a. Remove the screws (Figure 29) securing the float bowl to the carburetor. b. Slowly remove the float bowl body and with- draw the pump rod (Figure 30) from the boot on the bowl. c. Disconnect the pump rod from the lever as- sembly on the carburetor (Figure 31). NOTE One of the float pin pedestals has an interference fit that holds the float pin in place. An arrow, (Figure 32) cast 31 into the carburetor, points to this ped- estal. To remove this float pin, tap it out from the interference side in the direction of the arrow. CAUTION If the float pin is removed in the direc- tion opposite of the arrow, the oppo- site pedestal may crack or break off. If this occurs the carburetor must be re- placed. 7. Carefully tap the float pin (Figure 33) out of the pedestals and remove it. 32 8. Remove the float and needle valve assembly (Figure 34). 9. Unscrew and remove the pilot jet (Figure 35). 10. Unscrew and remove the main jet (Figure 36). 11. Unscrew and remove the needle jet holder (Fig- ure 37). 12. Remove the needle jet (A, Figure 38) from the needle jet bore in the carburetor. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 281 33 37 34 38 7 Cleaning and Inspection 35 Replace worn or damaged parts as described in this section. CAUTION The carburetor body is equipped with plastic parts that cannot be removed. Do not dip the carburetor body, O-rings, float assembly, needle valve or vacuum piston in a carburetor cleaner or other harsh solution that can damage these parts. The use of a caustic carburetor cleaning solvent is not recommended. Instead, clean the carburetor and related parts in a pe- 36 troleum-based solvent, or Simple Green. Then rinse in clean water. 1. Initially clean all parts in a mild petroleum based cleaning solution. Then clean in hot soap and water and rinse with cold water. Blow dry with com- pressed air. CAUTION If compressed air is not available, al- low the parts to air dry or use a clean ------------------------------------------------------------------------------------------------------------------------------------------------------------- 282 CHAPTER SEVEN 39 40 lint-free cloth. Do not use a paper towel to dry carburetor parts, as 41 small paper particles may plug open- ings in the carburetor housing or jets. 2. Allow the carburetor to dry thoroughly before assembly and blow dry with compressed air. Blow out the jets and the needle jet holder with com- pressed air. CAUTION Do not use wire or drill bits to clean jets as minor gouges in the jet can al- ter flow rate and upset the air/fuel mixture. 42 3. Inspect the float bowl O-ring gasket (A, Figure 39) for hardness or deterioration. 4. Inspect the accelerator pump boot (B, Figure 39) for hardness or deterioration. 5. Make sure the accelerator pump cover (Figure 40) screws are tight. 6. Inspect the vacuum piston diaphragm (Figure 41) for cracks, deterioration or other damage. Check the vacuum piston sides (Figure 42) for ex- cessive wear. Install the vacuum piston into the car- buretor body and move it up and down in the bore. The vacuum piston should move smoothly with no binding or excessive play. If there is excessive play, 43 the vacuum piston slide and/or carburetor body must be replaced. 7. Inspect the needle valve tapered end for steps, uneven wear or other damage (Figure 43). 8. Inspect the needle valve seat (B, Figure 38) for steps, uneven wear or other damage. Insert the nee- dle valve and slowly move it back and forth and check for smooth operation. If either part is worn or damaged, replace both parts as a pair for maximum performance. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 283 44 48 45 49 7 9. Inspect the needle jet holder, pilot jet and main 46 jet (Figure 44). Make sure all holes are open and none of the parts are either worn or damaged. 10. Inspect the jet needle, spring and spring seat (Figure 45) for deterioration or damage. 11. Inspect the jet needle tapered end for steps, un- even wear or other damage. 12. Inspect the float (Figure 46) for deterioration or damage. If the float is suspected of leakage, place it in a container of water and push it down. If the float sinks or if bubbles appear (indicating a leak), the float must be replaced. 13. Make sure the throttle plate (Figure 47) screws are tight. Tighten if necessary. 47 14. Move the throttle wheel (Figure 48) back and forth from stop to stop and check for free move- ment. The throttle lever should move smoothly and return under spring tension. 15. Check the throttle wheel return spring (Figure 49) for free movement. Make sure it rotates the throttle wheel back to the stop position with no hesi- tation. 16. Make sure all openings in the carburetor hous- ing are clear. Clean out if they are plugged in any way, then apply compressed air to all openings. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 284 CHAPTER SEVEN 50 51 17. Inspect the carburetor body for internal or ex- ternal damage. If damaged, replace the carburetor 52 assembly, as the body cannot be replaced sepa- rately. 18. Check the top cover for cracks or damage. 19. Check the starting enrichment valve and cable as follows: a. Check the end of the valve (Figure 50) for damage. b. Check the entire length of the cable for bends, chafing or other damage. c. Check the knob, nut and lock washer for dam- age. Move the knob and check for ease of movement. 53 Assembly NOTE The needle jet has two different sides and must be installed correctly as de- scribed in Step 1. 1. Position the needle jet with the long end going in first (Figure 51) and install it (A, Figure 38). 2. Install the needle jet holder (Figure 37) into the main jet passage. Make sure it passes through the 54 opening in the venturi (Figure 52), then tighten se- curely. 3. Install the main jet and tighten securely (Figure 36). 4. Install the pilot jet and tighten securely (Figure 35). 5. Install the fuel valve onto the float (Figure 53) and position the float onto the carburetor so that the valve drops into its seat. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 285 55 59 CAUTION 56 The pedestals that support the float pin are fragile. In the next step, sup- port the pedestal on the arrow side while tapping the float pin into place. 7 6. Align the float pin with the two pedestals. 7. Install the float pin (A, Figure 54) from the side opposite the arrow (B, Figure 54). Support the ped- estal and tap the float pin into place in the pedestal. 8. Check the float level as described in this chapter. 9. Install the float bowl as follows: a. Make sure the float bowl O-ring seal (A, Fig- ure 39) and accelerator rod boot (B) are in place. 57 b. Connect the pump rod onto the lever assem- bly on the carburetor (Figure 55). c. Slowly install the float bowl body and insert the accelerator pump rod through the boot (Figure 30) on the float bowl. Engage the rod with the diaphragm while installing the float bowl. d. Install the float bowl and screws (Figure 29) and tighten the screws securely in a crisscross pattern. 10. Insert the jet needle (Figure 56) through the center hole in the vacuum piston. 11. Install the spring seat (A, Figure 57) and spring 58 (B) over the top of the needle to secure it in place. 12. Align the slides (A, Figure 58) on the vacuum piston with the grooves (B) in the carburetor bore and install the vacuum piston (B, Figure 28). The slides on the piston are offset, so the piston can only be installed one way. When installing the vacuum piston, make sure the jet needle drops through the needle jet. 13. Seat the outer edge of the vacuum piston dia- phragm into the piston chamber groove (Figure 59). ------------------------------------------------------------------------------------------------------------------------------------------------------------- 286 CHAPTER SEVEN 60 61 FLOAT BASE POSITION Carburetor Float 14. Align the free end of the spring with the carbu- retor top and install the top onto the carburetor. 15. Hold the carburetor top in place and lift the vac- uum piston with a finger (Figure 60). The piston must move smoothly. If the piston movement is rough or sluggish, the spring is installed incorrectly. Remove the carburetor top and reinstall the spring. 16. Install the carburetor top three screws (Figure FLOAT ADJUSTMENT 62 27) finger-tight. POSITION 17. Install the collar (Figure 26) into the cover. 18. Install the throttle cable bracket (B, Figure 25) Carburetor onto the carburetor so that the end of the idle speed screw engages the top of the throttle cam stop (B, Figure 24). Hold the bracket in place and install the bracket’s side mounting screw and washer (A, Fig- ure 24). Tighten the screw securely. Float 19. Install the top screw (A, Figure 25) and tighten securely. 20. Install the starting enrichment cable and valve 0.413-0.453 in. into the carburetor body and tighten the nut securely (10.5-11.5 mm) (Figure 23). 15° to 20° Float Adjustment The carburetor must be removed and partially disassembled for this adjustment. 63 1. Remove the carburetor as described in this chap- ter. 2. Remove the float bowl as described in this chap- ter. 3. Place the engine manifold side of the carburetor on a clean flat surface as shown in Figure 61. This is the base position. 4. Tilt the carburetor upward 15-20° as shown in Figure 62. At this position, the float will come to rest without compressing the pin return spring. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 287 64 INTAKE MANIFOLD 7 1. Manifold seal 2. Flange 3. Intake manifold 4. Screw 5. Clip 6. MAP sensor 7. Seal 8. Bolt 9. Seal ring NOTE 9. Repeat these steps until the float level is correct. If the carburetor is tilted less than 15° 10. Install the float bowl and carburetor as de- or more than 20°, the float measure- scribed in this chapter. ment will be incorrect. 5. Measure from the carburetor flange surface to INTAKE MANIFOLD the top of the float as shown in Figure 62. When measuring float level, do not compress the float. Removal/Installation The correct float level measurement is 0.413-0.453 in. (10.5-11.5 mm). Refer to Figure 64. 6. If the float level is incorrect, remove the float pin 1. Remove the carburetor as described in this chap- and float as described under Carburetor Disassem- ter. bly in this chapter. NOTE 7. Slowly bend the float tang (Figure 63) with a The front and rear intake manifold screwdriver and adjust to the correct position. flanges are different. If the flanges are 8. Reinstall the float and the float pin as described not marked, label them with an F and under Carburetor Assembly in this chapter. Re- R so they will be reinstalled in the cor- check the float level. rect location. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 288 CHAPTER SEVEN 2. Disconnect the electrical connector from the MAP sensor (A, Figure 65) on top of the intake 65 manifold. NOTE Figure 65 shows only two of the Allen bolts. Remove all four bolts. 3. Remove the four Allen bolts (B, Figure 65) se- curing the intake manifold to the cylinder heads. 4. Remove the intake manifold, flanges and mani- fold seals. 5. Inspect the intake manifold as described in this section. 6. Install the flanges and manifold seals (Figure 66 66) onto the intake manifold. 7. Install the intake manifold onto the cylinder head intake ports. 8. Check that the front and rear seals seat squarely against the cylinder head mating surfaces. 9. Install all four Allen bolts finger-tight at this time. 10. Temporarily install the carburetor into the in- take manifold. CAUTION Do not attempt to align the intake manifold after tightening the bolts. 67 This will damage the manifold seals. If necessary, loosen the bolts, then align the manifold. 11. Check that the intake manifold seats squarely against the cylinder heads. Then check that the car- buretor seats squarely in the intake manifold. Re- move the carburetor. NOTE It is very difficult to get an Allen wrench and torque wrench onto the 14. Connect the electrical connector onto the MAP two inboard Allen bolts to tighten them to a specific torque value. sensor (A, Figure 65). Tighten the outboard Allen bolts to the 15. Install the carburetor as described in this chap- specified torque value, then tighten ter. the inboard Allen bolts to the same approximate tightness. Inspection 12. Tighten the intake manifold Allen bolts to the specification in Table 2. 13. If the MAP sensor was removed, install a new 1. Check the intake manifold seals (Figure 66) for seal in the manifold receptacle, then install the MAP wear, deterioration or other damage. Replace the sensor. seals as a set if necessary. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 289 68 70 THROTTLE CABLES 2. Check the intake manifold seal ring (Figure 67) for cracks, flat spots or other damage. Replace if necessary. 3. If necessary, remove the self-tapping screw and clamp and remove the MAP sensor. 7 THROTTLE AND IDLE CABLE REPLACEMENT There are two different throttle cables (Figure 68). One is the throttle control cable (A, Figure 69 and A, Figure 70) and the other is the idle control cable (B, Figure 69 and B, Figure 70). Figure 68 shows the throttle housing and cable assembly. The cables are identified as follows: a. Throttle control cable. 1. Handlebar 9. Ferrule b. Idle cable. 2. Upper housing 10. Clip 3. Lower housing 11. Throttle grip NOTE 4. Friction shoe 12. Throttle control The throttle control and idle control 5. Snap ring cable cables have differently sized threads 6. Spring 13. Boot on the cable’s threaded adjusters. 7. Adjusting screw 14. Idle control 8. Screw cable The throttle control cable has a 5/16-18 threaded adjuster. The idle control cable has a 1/4-20 threaded adjuster. 69 1. Remove the fuel tank as described in this chap- ter. 2. Remove the air filter and backing plate as de- scribed in this chapter. 3. Make a drawing or take a picture of the cable routing from the carburetor through the frame to the right side handlebar. 4. At the right side handlebar, perform the follow- ing: a. Slide the rubber boot off both cables. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 290 CHAPTER SEVEN 71 72 b. Loosen both control cable adjuster locknuts (A, Figure 71), then turn the cable adjusters 73 (B, Figure 71) clockwise as far as possible to increase cable slack. 5. Loosen the cable jam nuts (A, Figure 72) at the throttle housing. 6. Remove the screws (B, Figure 72) securing the upper and lower housings to the handlebar, then separate the housings. 7. Remove the friction pad (Figure 73) from the lower throttle housing. 8. Unhook the cables (Figure 74) from the throttle grip and remove the ferrule from the end of each ca- ble (Figure 75). 9. Pull the crimped inserts at the end of the throttle 74 and idle control cable housings from the switch lower housing. 10. Partially remove the carburetor, as described in this chapter, until the throttle cables can be discon- nected from the throttle wheel. 11. Disconnect the throttle control cable (A, Fig- ure 76) and the idle control cable (B) from the car- buretor cable guide and the throttle wheel (C). 12. Remove the cables from the frame. 13. Clean the throttle grip assembly and dry thor- oughly. Check the throttle slots for cracks or other damage. Replace the throttle if necessary. 14. The friction adjust screw is secured to the lower 75 switch housing with a snap ring. If necessary, re- move the friction spring, snap ring, spring and fric- tion adjust screw. Check these parts for wear or damage. Replace damaged parts and reverse to in- stall. Make sure the snap ring seats in the friction screw groove completely. 15. Clean the throttle area on the handlebar with solvent. 16. Apply a light coat of graphite to the housing in- side surfaces and to the handlebar. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 291 76 80 17. On the lower switch housing, push the larger 77 diameter silver throttle cable insert into the larger hole in front of the tension adjust screw. Push it in until it snaps into place. 18. Push the smaller diameter gold throttle cable in- 7 sert into the smaller hole in the rear of the tension adjust screw. Push it in until it snaps into place. 19. Install the friction pad (Figure 73) into the lower housing (Figure 78). Match the curvature on the friction pad with the handlebar. 20. Install a ferrule (Figure 75) onto the end of each cable, then insert the ferrules into the throttle grip slots (Figure 74). 78 NOTE If the master cylinder is not mounted on the handlebar, fit the throttle housing wiring harness into the depression (Fig- ure 79) in the bottom of the handlebar. 21. Assemble the upper and lower switch housings and the throttle grip. Install the lower switch hous- ing screws (B, Figure 72) and tighten securely. Op- erate the throttle and make sure both cables move in and out properly. 22. Route the cables from the handlebar to the car- buretor. 23. Connect the idle cable (B, Figure 70) to the 79 carburetor as follows: a. The idle cable has the small spring (A, Figure 80) on the end of the cable. b. Insert the idle cable sheath into the rear cable bracket guide on the carburetor (B, Figure 80). c. Attach the end of the idle cable into the throt- tle wheel (C, Figure 80). 24. Connect the throttle cable (A, Figure 70) to the carburetor as follows: ------------------------------------------------------------------------------------------------------------------------------------------------------------- 292 CHAPTER SEVEN 81 82 a. Insert the throttle cable sheath (A, Figure 76) into the front cable bracket guide on the car- 83 buretor. b. Attach the end of the throttle cable into the throttle wheel (C, Figure 76). 25. Operate the hand throttle a few times, making sure the throttle wheel operates smoothly with no binding. Also check that both cable ends are seated squarely in their cable bracket guides and in the throttle wheel. 26. Adjust the throttle and idle cables as described in Chapter Three. 27. Reinstall the carburetor as described in this 2. Note the routing of the enrichener cable from its chapter. mounting bracket to the carburetor. 28. Install the air filter backplate and air filter as 3. Loosen the locknut (A, Figure 81) and discon- described in this chapter. nect the starting enrichment valve cable to the 29. Install the fuel tank as described in this chapter. mounting bracket (B). Move the end of the cable out 30. Start the engine and allow it to idle in of the mounting bracket. NEUTRAL. Then turn the handlebar from side to 4. Partially remove the carburetor, as described in side. Do not operate the throttle. If the engine speed this chapter, until the starting enrichment valve ca- increases when turning the handlebar assembly, the ble can be disconnected from the backside of the throttle cables are routed incorrectly or damaged. carburetor. Recheck cable routing and adjustment. 5. Unscrew and remove the starting enrichment WARNING valve and cable (Figure 82) from the carburetor and Do not ride the motorcycle until the remove the cable from the frame. throttle cables are properly adjusted. 6. Install by reversing these removal steps while Improper cable routing and adjustment can cause the throttle to stick open. This noting the following: could cause loss of control. Recheck the a. Align the starting enrichment valve needle work before riding the motorcycle. (A, Figure 83) with the needle passage in the carburetor (B) and install the starting enrichment valve. Tighten the valve nut se- STARTING ENRICHMENT VALVE curely. (CHOKE) CABLE REPLACEMENT b. Position the starting enrichment valve cable 1. Remove the air filter and backplate as described into the mounting bracket (B, Figure 81), in Chapter Three. then tighten the locknut (A) securely. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 293 84 FUEL TANK (FXDP) 1. Screw 2. Ignition switch and key 3. Trim plate 4. Washer 5. Center console 6. Gasket 7. Mounting bracket 8. Nut clip 9. Clip 10. Pop rivet 7 11. Filler cap 12. Gasket 13. Bolt 14. Acorn nut 15. Fuel tank 16. Hose clamp 17. Interconnecting hose FUEL TANK hot part, leaking vapors may ignite, causing a fire. WARNING Some fuel may spill from the fuel tank Removal/Installation hose when performing this procedure. Because gasoline is extremely flam- The fuel hose is secured to the fuel tank with a mable and explosive, perform this non-reusable clamp. If the same type of clamp is go- procedure away from all open flames ing to be reinstalled, purchase one before servicing (including appliance pilot lights) and sparks. Do not smoke or allow some- the fuel tank. one who is smoking in the work area, Refer to Figure 84, Figure 85 and Figure 86 for as an explosion and fire may occur. fuel tank components and lines. Always work in a well-ventilated area. Wipe up any spills immediately. NOTE On models so equipped, always dis- WARNING arm the optional TSSM security sys- Make sure to route the fuel tank vapor tem prior to disconnecting the battery hoses so that they cannot contact any or the siren will sound. hot engine or exhaust component. These hoses contain flammable va- 1. Disconnect the negative battery cable from the pors. If a hose melts from contacting a battery. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 294 CHAPTER SEVEN 85 FUEL TANK (ALL MODELS EXCEPT FXDP) 1. Hose clamp 2. Interconnecting hose 3. Filler cap 4. Gasket 5. Bolt 6. Washer 7. Acorn nut 8. Fuel tank (FXDWG, FXDL) 9. Boot 10. Fuel tank (FXDS-CON, FXD, FXDX, FXDXT) 2. Remove the seat as described in Chapter Thir- a. Connect the drain hose to the fuel valve and teen. secure it with a hose clamp. Insert the end of 3. Turn the fuel valve to the OFF position (A, Fig- the drain hose into a gas can. ure 87). b. Disconnect the vacuum hose (Figure 88) 4. Remove the factory hose clamp and disconnect from the fuel valve. the fuel hose (B, Figure 87) from the valve. c. Connect a hand-operated vacuum pump (Fig- ure 89) to the fuel valve vacuum hose fitting. NOTE d. Turn the fuel valve to the RES position. On some models, a crossover tube connects the two fuel tanks. Drain the CAUTION tanks before removing them in the fol- In the following step, do not apply lowing steps. more vacuum than 25 in. (635 mm) Hg or the fuel valve diaphragm will be 5. Drain the fuel tank as follows: damaged. NOTE e. Gently operate the vacuum pump handle and All models have a vacuum-operated fuel valve installed. A hand-operated apply up to a maximum of 25 in. (635 mm) Hg vacuum pump is required to drain the of vacuum. Once the vacuum is applied the fuel tank. fuel will start to flow into the gas can. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 295 86 FUEL TANK LINES AND 88 FITTINGS (ALL MODELS) 89 7 f. When fuel stops flowing through the hose, turn the fuel valve off and release the vacuum. Disconnect the vacuum pump and drain hose. 6. Disconnect the vent hose from the fuel tank. 8. Fuel hose (to 7. On FXDP models, perform the following: 1. Hose carburetor) a. Remove screws and washers securing the 2. Hose clamp 9. Hose clamp 3. Vapor valve 10. Filter center console and remove the console. 4. Vent tube 11. Hex fitting b. Disconnect all remaining electrical connec- 5. Hose insulator 12. Gasket tors. Move the connectors and harness wires 6. Connector 13. Shutoff valve out of the way. 7. Vacuum hose 14. Hose c. Remove the screw and washer securing the center console at the rear of the tank. 8. Disconnect the electrical connectors leading from the gauges mounted on the fuel tank. 87 9. Disconnect the crossover hose from one side of the fuel tank. Plug the tank opening and apply a hemostat to the crossover hose (Figure 90). 10. Remove the nuts, washers and bolts (Figure 91) securing the fuel tank to the frame. 11. Lift off and remove the fuel tank. NOTE Store the fuel tank in a safe place—away from open flames or where it could be damaged. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 296 CHAPTER SEVEN 12. Drain any remaining fuel left in the tank into a gas can. 90 13. Installation is the reverse of these steps while noting the following: a. Tighten the front and rear bolts and nuts to the specification in Table 2. b. Reconnect the fuel hose to the fuel valve and secure it with a new hose clamp. c. Refill the tank and check for leaks. Inspection 1. Inspect all of the fuel and vent hoses for cracks, deterioration or damage. Replace damaged hoses 91 with the same type and size materials. The fuel line must be flexible and strong enough to withstand en- gine heat and vibration. 2. Check the fuel line insulator for damage. 3. Check for damaged fuel tank mounting brackets. Refer to Figure 92 and Figure 93, typical. 4. Remove the filler cap (Figure 94, typical) and inspect the tank for rust or contamination. If there is rust buildup inside the tank, clean and flush the tank as described in this chapter. 5. Inspect the fuel tank for leaks. 92 FUEL SHUTOFF VALVE A three-way vacuum-operated fuel shutoff valve is mounted to the left side of the fuel tank. A re- placeable fuel filter is mounted to the top of the fuel shutoff valve (Figure 95). To troubleshoot this valve, refer to Vacuum Oper- ated Fuel Shutoff Valve Testing in Chapter Two. Removal WARNING Gasoline is very volatile and presents 93 an extreme fire hazard. Be sure to work in a well-ventilated area away from any open flames (including pilot lights on household appliances). Do not allow anyone to smoke in the area and have a fire extinguisher rated for gasoline fires nearby. 1. Disconnect the negative battery cable from the battery. 2. Turn the fuel shutoff valve to the OFF position. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 297 3. Drain the fuel tank as described under Fuel Tank 94 Removal/Installation in this chapter. NOTE The fuel shutoff valve can be removed with the fuel tank in place. Figure 96 is shown with the fuel tank removed to better illustrate the step. 4. Loosen the fuel valve fitting (A, Figure 96) and remove the fuel shutoff valve (B) from the fuel tank. Drain any residual gasoline that may still be in the tank after the valve is removed. 95 VACUUM-OPERATED Cleaning and Inspection FUEL VALVE 1. Inspect the filter mounted on top of the fuel 7 valve. Remove and clean the filter of all contamina- tion. Replace the filter if damaged. 2. Install a new filter gasket before installing the filter onto the fuel valve. 3. Remove all sealant residue from the fuel tank Fuel filter and fuel valve threads. Installation Fitting 1. Install a new filter gasket onto the fuel shutoff Handle valve, then install the filter. 2. Coat the fuel valve threads with Loctite pipe sealant. 3. Insert the fuel valve into the tank, then tighten the hex fitting onto the fuel tank two turns. Hose 4. Hold the hex fitting and tighten the fuel valve (left-hand threads) two turns into the hex fitting. 5. Hold the fuel valve and tighten the hex fitting to the specification in Table 2. WARNING 96 If the hex fitting is turned more than two turns on the valve, it may bottom out on the valve and cause a fuel leak. This could result in a dangerous fire. 6. Install the insulator tube over the fuel hose. 7. Reconnect the fuel hose to the fuel shutoff valve and secure it with a hose clamp. 8. Refill the fuel tank and check for leaks. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 298 CHAPTER SEVEN FUEL TANK GAUGE 97 FUEL GAUGE ASSEMBLY WARNING (FXD, FXDS-CONV, Because gasoline is extremely flam- FXDX 1999-2000) mable and explosive, perform this procedure away from all open flames (including appliance pilot lights) and sparks. Do not smoke or allow some- one who is smoking in the work area, as an explosion and fire may occur. Always work in a well-ventilated area. Wipe up any spills immediately. Removal/Installation (FXD, FXDS-CONV, FXDX [1999-2000]) 1. Screw Refer to Figure 97. 2. Retainer 1. Remove the fuel tank as described in this chap- 3. Screw ter. 4. Trim panel 5. Fuel gauge 2. Remove the gas filler cap. 6. Screw 3. Remove the five screws securing the fuel gauge 7. Bulb retainer. Remove the retainer. 8. Trim panel ring 4. Use a flat-blade screwdriver and carefully pry 9. Sending unit 10. Gasket the fuel gauge loose from the sending unit. 5. Withdraw the fuel gauge from the sending unit. 6. Remove the five screws and washers securing the sending unit to the fuel tank. 98 FUEL GAUGE ASSEMBLY CAUTION (FXDL, FXDWG 1999-2000) Do not bend the float arm during re- moval of the sending unit. If bent, the gauge will give inaccurate readings. 7. Carefully withdraw the sending unit while mov- ing it back and forth, lifting and turning it in either direction. 8. Remove the gasket from the fuel tank. 9. Install by reversing these removal steps while noting the following: a. Install a new gasket between the sending unit and fuel tank. b. Carefully install the sending unit to avoid damage to the float arm. c. Tighten all screws securely. Removal/Installation 1. Screw (FXDL, FXDWG [1999-2000]) 2. Sending unit 3. Fuel gauge 4. Bulb Refer to Figure 98. 5. Gasket 1. Remove the fuel tank as described in this chap- 6. Harness ter. ------------------------------------------------------------------------------------------------------------------------------------------------------------- FUEL, EXHAUST AND EMISSION SYSTEMS 299 99 FUEL GAUGE ASSEMBLY (FXD, FXDX, FXDXT 2001) 1. Fuel gauge 2. Screw 3. Terminal socket 4. Retainer 5. Screw 6. Trim panel 7. Trim edging 8. Pin housing 9. Terminal socket 10. Trim panel ring 11. Screw 7 12. Socket housing 13. Terminal socket 14. Gasket 15. Sending unit NOTE 6. Carefully withdraw the sending unit while mov- The fuel gauge electrical wires are ing it back and forth, lifting and turning it in either routed through a tube in the fuel tank direction. and are secured with a clamp at the 7. Remove the gasket from the fuel tank. bottom of the fuel tank. Loosen the 8. Install by reversing these removal steps while clamp and make sure there is enough slack in the wires to allow the gauge to noting the following: be pulled up and out of the fuel tank. a. Install a new gasket between the fuel gauge and fuel tank. 2. Pull straight up on the gauge and partially re- b. Carefully install the sending unit to avoid move it from the tank. damage to the float arm. 3. Disconnect the electrical connector from the c. Tighten all screws securely. wires within the fuel tank. Do not disconnect the electrical wires from the fuel gauge. 4. Remove the fuel gauge and the gasket. Removal/Installation 5. Remove the five screws securing the sending (FXD, FXDX, FXDXT [2001]) unit to the fuel tank. Refer to Figure 99. CAUTION 1. Remove the fuel tank as described in this chap- Do not bend the float arm during re- ter. moval of the sending unit. If bent, the gauge will give inaccurate readings. 2. Remove the gas filler cap (A, Figure 100). | |
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