532
SUPPLEMENT
CAUTION
Failure to install the spacer in Step 7
59
will result in damage to the rubber boot
and plunger on the front brake switch.
7. Insert a 5/32 in. (4 mm) thick spacer between the
brake lever and lever bracket. Make sure the spacer
stays in place during the following steps.
8. Remove the screws securing the right side switch
assembly together (A, Figure 59).
9. Remove the front master cylinder (B, Figure 59)
as described in Chapter Twelve.
10. Remove the brass ferrules from the notches on
3. Push the smaller diameter gold throttle cable insert
the inboard side of the throttle grip (Figure 60). Re-
into the smaller hole in the rear of the tension adjust-
move the ferrules from the cable end fittings.
ing screw. Push it in until it snaps into place.
11. Remove the friction shoe from the end of the ten-
4. Position the friction shoe with the concave side
sion adjusting screw.
facing up and install it so the pin hole is over the point
of the adjuster screw.
12. Remove the throttle grip from the handlebar.
5. Install the throttle grip onto the handlebar. Push it
NOTE
on until it stops, and pull it back about 1/8 in. (3.2
Use a rocking motion while pulling on
mm). Rotate it until the ferrule notches are at the top.
the control cable housings in Step 13. If
6. Place the lower switch housing below the throttle
necessary, place a drop of engine oil on
grip. Install the brass ferrules onto the cables so the
the housings retaining rings to ease
end fittings seat in the ferrule recess. Seat ferrules in
removal.
their respective notches on the throttle control grip.
Make sure the cables are captured in the molded
13. Pull the crimped inserts at the end of the throttle
grooves in the grip.
and idle control cable housings from the switch lower
7. Assemble the upper and lower switch housings
housing.
and the throttle grip. Install the lower switch housing
14. Remove the cables from the frame.
screws (A, Figure 59) and tighten them finger-tight.
15. Clean the throttle grip assembly and dry it thor-
8. If it is not in place, insert the 5/32 in. (4 mm) thick
oughly. Check the throttle slots for cracks or other
spacer between the brake lever and lever bracket.
damage. Replace the throttle if necessary.
Make sure the spacer stays in place during the follow-
16. The friction adjust screw is secured to the lower
ing steps.
switch housing with a circlip. If necessary, remove the
9. Install the front master cylinder (B, Figure 59)
friction spring, circlip, spring and friction adjust
as described in Chapter Twelve.
screw. Check these parts for wear or damage. Replace
10. Securely tighten the switch housing screws.
damaged parts and reinstall. Make sure the circlip
11. Remove the cardboard insert from the front mas-
seats in the friction screw groove completely.
ter cylinder.
17. Clean the throttle area on the handlebar with sol-
12. Operate the throttle and make sure both cables
vent.
move in and out properly.
13. Correctly route the cables from the handlebar to
Installation
the induction module.
14. At the induction module, perform the following:
1. Apply a light coat of graphite to the housing inside
a. Install the idle cable (B, Figure 58) ball end
surfaces and to the handlebar.
over the top of the throttle barrel (C) and install
2. On the lower switch housing, push the larger diam-
the cable ball end into the upper hole in the
eter silver throttle cable insert into the larger hole in
throttle barrel. Make sure it is properly seated.
front of the tension adjust screw. Push it in until it
b. Install the throttle cable (A, Figure 58) ball end
snaps into place.
under the bottom of the throttle barrel (C) and
2002-2005 MODEL SERVICE INFORMATION
533
NOTE
60
On models so equipped, always disarm
the optional TSSM security system
prior to disconnecting the battery or the
siren will sound.
1. Disconnect the negative battery cable as described
in Chapter Eight.
2. Remove the seat as described in Chapter Thirteen.
NOTE
It is not necessary to remove the five
short rings since they secure the top
install the cable ball ends into the lower hole in
plate trim ring to the base of the con-
sole.
the throttle barrel. Make sure they are properly
seated.
3. Remove the three long screws securing the fuel
c. Install the cables into the integral cable guides
cap trim ring and console to the top plate.
in the induction module.
4. Pull the fuel cap trim ring straight up and remove it.
15. At the throttle grip, tighten the cables to keep the
5. Remove the screw securing the rear portion of the
ball ends from being disconnected from throttle bar-
console. Pull the console and trim/gasket straight up
rel.
and remove it from the fuel tank.
16. Operate the hand throttle a few times. Make sure
6. If necessary, remove the fuel filler cap and O-ring
the throttle barrel operates smoothly with no binding.
from the top plate.
Also make sure both cable ends are seated squarely in
7. To remove the fuel gauge, perform the following:
their cable bracket guides and in the throttle barrel.
a. Remove the front and rear bolts, washers and
17. Adjust the throttle and idle cables as described in
acorn nuts securing the fuel tank.
Chapter Three.
b. Raise the fuel tank. On the left side, disconnect
18. Install the backing plate and air filter as described
the fuel gauge electrical connector from the
in Chapter Three.
main harness.
c. Pull the fuel gauge straight and gasket up and
19. Install the fuel tank as described in this chapter.
out of the top plate.
WARNING
8. Install the fuel gauge as follows:
Do not ride the motorcycle until the
a. Install the fuel gauge and new gasket into the
throttle cables are properly adjusted.
top plate.
Improper cable routing and adjustment
b. Connect the fuel gauge electrical connector
can cause the throttle to stick open. This
onto the main harness.
could cause loss of control.
14
c. Lower the fuel gauge and install the bolts,
washers and acorn nuts. Tighten the bolts and
20. Start the engine and allow it to idle in neutral.
nuts to 15-20 ft.-lb. (20-27 N•m).
Then turn the handlebar from side to side. Do not op-
9. If removed, install the fuel filler cap and O-ring
erate the throttle. If the engine speed increases when
onto the top plate.
turning the handlebar assembly, the throttle cables are
10. Install the trim/gasket onto the console and make
routed incorrectly or are damaged. Recheck cable
sure it is correctly seated around the console perimeter.
routing and adjustment.
11. Install console and trim/gasket straight onto the
fuel tank. Make sure it is correctly seated, and install
FUEL TANK CONSOLE
the screw securing the rear portion. Tighten the screw
to 18-24 in.-lb. (2.0-2.7 N•m).
Removal/Installation
12. Position the slot in the fill cap trim cap over the
(FXD, FXDI, FXDX, FXDXI Models)
tab on the console and install the trim cap.
13. Install the three long screws securing the fuel cap
Refer to Figure 61.
trim ring and console to the top plate. Tighten the
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534
SUPPLEMENT
61
FUEL TANK CONSOLE
(FXD, FXDI, FXDX, FXDXI)
1. Screw
2. Screw
3. Fuel fill cap trim ring
4. Console
5. Mounting ring
6. Trim gasket
7. Top plate trim ring
8. Filler cap
9. Gasket
10. Top plate
11. Fuel restrictor
12. Screw
13. Gasket
14. Wiring harness
15. Fuel gauge
(FXDX, FXDXI models)
16. Connector
17. Connector
18. Fuel gauge
(FXD, FXDI models)
19. Gasket
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2002-2005 MODEL SERVICE INFORMATION
535
screws to 18-22 in.-lb. (2.03-2.5 N•m). If the remain-
3. Remove the rear screw securing the leather trim
ing five screws were removed, tighten them to 18-22
panel to the fuel tank.
in.-lb. (2.03-2.5 N•m).
4. Place a towel on top of the fuel tank to protect the
14. Install the seat as described in Chapter Thirteen.
finish.
5. Remove the two screws securing the middle por-
tion of the console. Pull the console and trim/gasket
Removal/Installation
straight up and remove it from the fuel tank.
(FXDL, FXDLI Models)
6. Raise the fuel tank. Disconnect the speedometer
Refer to Figure 62.
and indicator lamp connectors from the main harness.
7. Install by reversing these removal steps. Note the
NOTE
following:
On models so equipped, always disarm
a.
Install the trim/gasket onto the console and
the optional TSSM security system
make sure it is correctly seated around the con-
prior to disconnecting the battery or the
sole perimeter.
siren will sound.
b.
Install console and trim/gasket straight onto the
1. Disconnect the negative battery cable as described
fuel tank. Make sure it is correctly seated.
in Chapter Eight.
c.
Install the mounting screws and tighten
to
2. Remove the seat as described in Chapter Thirteen.
18-24 in.-lb. (2.0-2.7 N•m).
3. Place a towel on top of the fuel tank to protect the
finish.
FUEL TANK
4. Remove the three screws securing the middle and
(2004-ON CARBURETED MODELS)
rear portion of the console. Pull the console and
trim/gasket straight up and place it on top of the fuel
WARNING
tank.
Some fuel may spill from the fuel tank
5. Disconnect the 12-pin electrical connector from
hose when performing this procedure.
both the speedometer and the tachometer.
Because gasoline is extremely flam-
6. Install by reversing these removal steps. Note the
mable and explosive, perform this
following:
procedure away from all open flames,
a. Install the trim/gasket onto the console and
including appliance pilot lights, and
make sure it is correctly seated around the con-
sparks. Do not smoke or allow anyone
sole perimeter.
to smoke in the work area, as an ex-
plosion and fire may occur. Always
b. Install console and trim/gasket straight onto the
work in a well-ventilated area. Wipe
fuel tank. Make sure it is correctly seated.
up any spills immediately.
c. Install the mounting screws and tighten to
18-24 in.-lb. (2.0-2.7 N•m).
WARNING
14
Route the fuel tank vapor hoses so that
they cannot contact any hot engine or
Removal/Installation
exhaust component. These hoses con-
(FXDWG, FXDWGI Models)
tain flammable vapors. If a hose melts
from contacting a hot part, leaking va-
Refer to Figure 63.
pors may ignite, causing a fire.
NOTE
On models so equipped, always disarm
Removal/Installation
the optional TSSM security system
prior to disconnecting the battery or the
The fuel hose is secured to the fuel tank
with
siren will sound.
non-reusable clamps. If the same type of clamp is go-
1. Disconnect the negative battery cable as described
ing to be reinstalled, purchase new ones before servic-
in Chapter Eight.
ing the fuel tank.
2. Remove the seat as described in Chapter Thirteen.
Refer to Figure 64.
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536
SUPPLEMENT
62
FUEL TANK CONSOLE
(FXDL, FXDLI)
1. Tachometer
9. Reset switch rubber boot
2. Socket
10. Console
3. Gasket
11. Wiring harness
4. Screw
12. Clamp
5. Speed nut
13. Connector (12-pin)
6. Speedometer
14. Warning light
7. Socket
15. Back clamp
8. Gasket
16. Screw
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2002-2005 MODEL SERVICE INFORMATION
537
63
FUEL TANK CONSOLE
(FXDWG, FXDWGI)
14
1. Speedometer
10. Ignition switch
2. Gasket
11. Screw
3. Bezel
12. Back clamp
4. Indicator lamp bezel
13. Indicator lamp assembly
5. Screw
14. Connector
6. Console
15. Trim gasket
7. Leather trim panel
16. Reset switch
8. Speed nut
17. Reset switch rubber
9. Push nut
boot
-------------------------------------------------------------------------------------------------------------------------------------------------------------
538
SUPPLEMENT
64
FUEL TANK-CARBURETED MODELS (2004-ON)
1. Vent hose-
13. Filter
fuel tank-to-vapor valve
14. Gasket
2. Bolt
15. Fuel shutoff valve
3. Filler cap
16. Hose clamp
4. Gasket
17. Fuel hose
5. Washer
18. Insulator
6. Clip
19. Vacuum hose
7. Acorn nut
20. Crossover hose
8. Fuel tank
21. Vent hose-
9. Acorn nut
vapor valve-to-atmosphere
10. O-ring
22. Clip
11. Adaptor
23. Vapor valve
12. Nut
-------------------------------------------------------------------------------------------------------------------------------------------------------------
2002-2005 MODEL SERVICE INFORMATION
539
NOTE
65
A crossover tube connects the two fuel
tank compartments. Drain both sides of
the tank before removing the tank in the
following steps.
5.
Drain the fuel tank as follows:
NOTE
A vacuum-operated fuel valve is in-
stalled on all carbureted models. A
hand-operated vacuum pump is re-
quired to drain the fuel tank.
a. Connect the drain hose to the fuel valve and se-
66
cure it with a hose clamp. Insert the end of the
drain hose into a gas can.
b. Disconnect the vacuum hose (Figure 66) from
the fuel valve.
c. Connect a hand-operated vacuum pump (Fig-
ure 67) to the fuel valve vacuum hose fitting.
d. Turn the fuel valve to the RES position.
CAUTION
In the following step, do not apply more
vacuum than 25 in. (635 mm) Hg or the
fuel valve diaphragm will be damaged.
e. Gently operate the vacuum pump handle and
67
apply up to a maximum of 25 in. (635 mm) Hg
of vacuum. Once the vacuum is applied the
fuel will start to flow into the gas can.
f. When fuel stops flowing through the hose, turn
the fuel valve off and release the vacuum. Dis-
connect the vacuum pump and drain hose.
6.
Disconnect the vent hose from the fuel tank.
7.
Disconnect the crossover hose from one side of the
14
fuel tank. Plug the tank opening and apply a hemostat
to the crossover hose.
8. Remove the front and rear bolts, washers and acorn
NOTE
nuts securing the fuel tank to the frame.
On models so equipped, always disarm
9. If the fuel tank console is still in place, perform the
the optional TSSM security system
following:
prior to disconnecting the battery or the
a. Partially lift off and remove the fuel tank.
siren will sound.
b. On the left side, disconnect the fuel gauge elec-
trical connector.
1.
Disconnect the battery negative cable.
10. Lift off and remove the fuel tank.
2.
Remove the fuel tank console as described in this
section, if necessary.
NOTE
3. Turn the fuel valve (A, Figure 65) to the OFF position.
Store the fuel tank in a safe place away
4. Remove the hose clamp and disconnect the fuel
from open flames or where it could be
hose (B, Figure 65) from the valve.
damaged.
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