Harley Davidson 2018 softail models. Service manual — page 22
1. See Figure 1. Install upper vent line.
a. Connect upper vent line (2) to fuel tank.
b. Connect upper vent line to vapor valve (3).
c. Install new cable strap (1).
2. Install lower vent line.
a. Install lower vent line (4).
b. Connect lower vent line to vapor valve.
1
Cable strap
2
Upper vent line
3
Vapor valve
4
Lower vent line
Figure 1. Fuel Tank Vent Line
1. Install battery tray, if removed. See Prepare.
2. Install battery, if removed. See Prepare.
3. Install right side cover, if removed. See Remove.
4. Install seat. See Remove.
5. Install main fuse. See Main Fuse.
6. Install left side cover. See Remove.
1. Remove left side cover. See Remove.
1. See Vapor Valve. Remove vapor valve.
a. Remove vent lines (1) from vapor valve (3).
b. Pull vapor valve from clip (2).
WARNING
Excessive pressure can build in the fuel tank if vapor valve is not mounted vertically with long fitting to top. Leaks due
to excessive pressure can cause a fire or explosion, which could result in death or serious injury. (00265a)
1. See Figure 1. Install vapor valve.
a. Press vapor valve (3) into clip (2).
b. Install vent lines (1).
1
Vent lines
2
Clip
3
Vapor valve
Figure 1. Vapor Valve
1. Install left side cover. See Remove.
WARNING
Gasoline is extremely flammable and highly explosive. Keep gasoline away from ignition sources which could result in
death or serious injury. See the Safety chapter. (00635c)
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or serious injury. (00275a)
1. Remove seat. See Remove.
2. Remove fuel tank. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove air cleaner. See Remove.
5. Remove air cleaner backplate assembly. See Prepare.
1. Disconnect TMAP sensor connector.
2. See TMAP Sensor . Remove TMAP sensor.
a. Remove screw (2).
b. Remove TMAP sensor (1).
1. See Figure 1. Install TMAP sensor.
a. Install TMAP sensor (1).
b. Install screw (2). Tighten to 2.5-4.5 N·m (23-39 in-
lbs).
2. Connect TMAP sensor connector.
1
TMAP sensor
2
Screw
Figure 1. TMAP Sensor
1. Install air cleaner backplate assembly. Prepare.
2. Install air cleaner. Remove.
3. Install fuel tank. See Prepare.
4. Install seat. See Remove.
5. Install main fuse. See Main Fuse.
WARNING
Gasoline is extremely flammable and highly explosive. Keep gasoline away from ignition sources which could result in
death or serious injury. See the Safety chapter. (00635c)
1. Remove seat. See Remove.
2. Purge fuel system. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove fuel tank. See Prepare.
5. Remove frame plug and slide front electrical caddy away from backbone. See Prepare.
6. Remove right handlebar switch housing from handlebar. See Prepare
7. Remove right hand grip.
1. See TGS Connector. Disconnect TGS (Twist grip sensor) connector (2)
2. Remove cable straps and note location for installation.
3. Remove TGS.
a. Attach a chaser wire to the TGS connector
b. Remove TGS.
c. Pull TGS harness out of handlebar.
1.
NOTE
See Figure 2 The seal cap protects the TGS (Twist
grip sensor) terminals from dirt and moisture. It also
serves as a retention device for the throttle grip.
Install seal cap at end of TGS.
a. Check condition of O-ring on seal cap, replace if
necessary.
b. See Figure 2 Install seal cap engaging legs in slots at
end of TGS.
2. Install TGS.
a. Attach chaser wire used during removal to newTGS
connector.
b. Draw harness into handlebar while guiding TGS into
end into end of handlebar.
c. See Figure 3 Verify TGS is engaged into alignment
slots in handlebar.
3. See Figure 1 Connect TGS connector (2).
4. Install new cable straps.
1
Frame plug
2
TGS connector
3
Heated hand grip connector
Figure 1. TGS Connector
Figure 2. Install Seal Cap (Models without heated grips)
Figure 3. Install Twist Grip Sensor
1. Install right handgrip.
2. Install right handlebar switch housing. See Prepare.
3. Install front electrical caddy and frame plug. See Prepare.
4. Install fuel tank. See Prepare.
5. Install seat. See Remove.
6. Install main fuse. See Main Fuse.
WARNING
Gasoline is extremely flammable and highly explosive. Keep gasoline away from ignition sources which could result in
death or serious injury. See the Safety chapter. (00635c)
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely
flammable and highly explosive, which could result in death or serious injury. (00275a)
1. Remove seat. See Remove.
2. Purge fuel system. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove fuel tank. See Prepare.
5. Remove air cleaner. See Remove.
6. Remove air cleaner backplate assembly. See Prepare.
1. Disconnect fuel injector connectors.
2. See Fuel Injectors. Remove fuel rail and fuel injectors.
a. Remove screws (1).
b. Remove fuel rail (3).
c. Remove fuel injectors (2, 4).
3. Discard O-rings from intake manifold.
1. See Figure 1. Install fuel injectors to intake manifold.
a. Install new O-rings into intake manifold.
b. Install fuel injectors (2,4) to intake manifold.
2. Install fuel rail.
a. Install fuel rail (3).
b. Install screws (1). Tighten.
Torque: 3.5-5.5 N·m (31-49 in-lbs) Fuel rail screws
3. Connect fuel injector connectors.
a. Grey connector to front injector.
b. Black connector to rear injector.
1
Screw (2)
2
Rear fuel injector
3
Fuel rail
4
Front fuel injector
Figure 1. Fuel Injectors
1. Install air cleaner backplate assembly. See Prepare.
2. Install air cleaner. See Remove.
3. Install fuel tank. See Prepare.
4. Install seat. See Remove.
5. Install main fuse. See Main Fuse.
WARNING
Gasoline is extremely flammable and highly explosive. Keep gasoline away from ignition sources which could result in
death or serious injury. See the Safety chapter. (00635c)
1. Remove seat. See Remove.
2. Purge fuel system. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove fuel tank. See Prepare.
5. Remove air cleaner. See Remove.
6. Remove air cleaner backplate assembly. See Prepare.
Special Tools
Description
Part Number
Qty.
INTAKE MANIFOLD WRENCH
HD-47250
1
1. California models: See Figure 1. Pull purge tube from fitting (13).
2. Disconnect connectors:
a. Remove TMAP sensor connector (10).
b. Remove front fuel injector connector (8).
c. Remove rear fuel injector connector (5).
d. Remove TCA connector (11).
e. Release harness from anchor point (12).
NOTE
See Figure 2. For best results, use the INTAKE MANIFOLD WRENCH (Part Number:HD-47250).
3. See Figure 1. Remove right side screws (3).
4. Loosen left side screws (4).
5. Remove induction module from right side.
6. Discard seals (1).
7. Remove flange adapters (2, 9).
8. Disconnect fuel line from induction module.
a. Remove screw (6).
b. Pull fuel line from fuel rail inlet.
c. Discard O-ring (7).
1
Seal (2)
2
Rear flange adapter
3
Right side screw (2)
4
Left side screw (2)
5
Rear fuel injector connector
6
Screw
7
O-ring
8
Front fuel injector connector
9
Front flange adapter
10
TMAP sensor connector
11
TCA connector
12
TCA harness anchor point
13
Purge tube fitting/cap
Figure 1. Induction Module Assembly
Figure 2. Intake Manifold Wrench
Special Tools
Description
Part Number
Qty.
INTAKE MANIFOLD WRENCH
HD-47250
1
1.
Connect fuel line to induction module.
a. See Induction Module Assembly. Install new O-ring
(7).
b. Push fuel line firmly onto fuel rail inlet.
c. Install screw (6). Tighten.
Torque: 2.5-4.5 N·m (22-40 in-lbs) Fuel line to fuel
rail screw
2.
With the counterbore facing outward, install flange
adapters (2, 9) onto the induction module.
3.
Place new seal (1) in each flange adapter with the
beveled side against the counterbore.
NOTE
For best results, use the INTAKE MANIFOLD
WRENCH (Part Number:HD-47250).
4.
Install induction module.
a. Slide induction module into position until slots engage
left side screws (4).
b. Start right side screws (3).
c. Temporarily fasten mounting bracket to cylinder
heads with breather bolts.
5.
Tighten right side screws (3) until snug.
6.
Tighten left side screws (4).
Torque: 10.9-17.6 N·m (96-156 in-lbs) Induction module
flange adapter screws
7.
Tighten right side screws (3).
Torque: 10.9-17.6 N·m (96-156 in-lbs) Induction module
flange adapter screws
8.
Install connectors:
a. Install rear fuel injector connector (5) (black).
b. Install front fuel injector connector (8) (grey).
c. Install TMAP sensor connector (10).
d. Install TCA connector (11).
9.
Capture TCA harness to anchor point (12) with new
anchored cable strap.
10. California models: Connect purge tube to fitting (13).
11. Non-California models: Inspect rubber cap for damage.
Replace as necessary.
Throttle Body
NOTE
The throttle body can be removed without removing the entire induction module.
1. Induction module still installed: Disconnect TCM connector.
2. See Induction Module Assembly Remove bracket (1).
a. Remove screws (2).
b. Remove bracket.
3. Remove throttle body (4).
a. Remove screws (3).
b. Remove throttle body.
c. California models: Disconnect vent hose.
d. Discard gasket (6).
Induction Manifold
1. See Induction Module Assembly. Remove TMAP sensor (7). See Prepare.
2. Remove fuel rail (9) and fuel injectors (8, 10). See Prepare.
Induction Manifold
1. See Figure 1. Install TMAP sensor (7). See Prepare.
2. Install fuel injectors (8, 10) and fuel rail (9). See
Prepare.
Throttle Body
1. See Figure 1. Install throttle body (4).
a. Install new gasket (6).
b. Install throttle body.
c. Install screws (3).
Torque: 4-6 N·m (35-53 in-lbs) Throttle body to
manifold screws
d. If removed, install new rubber cap (5) or connect
vent hose.
2. Install bracket (1) with screws (2).
Torque: 7.5-9.5 N·m (66-84 in-lbs) Induction module
bracket
3. Induction module still installed: Connect TCM
connector.
1
Bracket
2
Screw (2)
3
Screw (3)
4
Throttle body
5
Rubber cap
6
Gasket
7
TMAP sensor
8
Rear fuel injector
9
Fuel rail
10
Front fuel injector
11
Intake manifold
Figure 1. Induction Module Assembly
1. Install air cleaner backplate assembly. See Prepare.
2. Install air cleaner. See Remove.
3. Install fuel tank. See Prepare.
4. Install seat. See Remove.
5. Install main fuse. See Main Fuse.
Special Tools
Description
Part Number
Qty.
PROPANE ENRICHMENT KIT
HD-41417
1
WARNING
Do not allow open flame or sparks near propane. Propane is extremely flammable, which could cause death or serious
injury. (00521b)
WARNING
Read and follow warnings and directions on propane bottle. Failure to follow warnings and directions can result in
death or serious injury. (00471b)
Parts List
Small propane cylinder.
PROPANE ENRICHMENT KIT (Part Number:HD-41417).
Tester Assembly
1. See Leak Tester. Make sure valve knob (6) is closed (fully clockwise).
2. Install valve assembly (5) onto propane bottle (1).
Tester Adjustment
1. See Leak Tester. Press and hold trigger button (8).
2. Slowly open valve knob (6) until pellet in flow gauge (7) rises 5-10 SCFH on gauge.
3. Release trigger button.
NOTE
Propane injected into air cleaner causes false readings. Keep air cleaner cover installed.
1. Run motorcycle until engine is at normal operating temperature.
2. Aim nozzle toward possible sources of leak.
NOTE
The tone of the engine changes when propane enters source of leak.
3. Press and release trigger button to dispense propane.
4. Repeat as necessary to detect leak.
5. When test is finished, close valve.
1
Propane bottle
2
Nozzle
3
Copper tube
4
Hose
5
Valve assembly
6
Valve knob
7
Flow gauge
8
Trigger button
9
Hanger
Figure 1. Leak Tester
1. Remove main fuse. See Main Fuse.
NOTE
Right side cover removal only necessary if replacing rear HO2S (Heated oxygen sensor).
2. Remove right side cover. See Remove.
Special Tools
Description
Part Number
Qty.
OXYGEN SENSOR WRENCH
HD-50017
1
1. See Front HO2S (Heated Oxygen Sensor) or Rear HO2S (Heated Oxygen Sensor). Disconnect HO2S (Heated
oxygen sensor) connector (1).
2. Remove HO2S (2) with OXYGEN SENSOR WRENCH (Part Number:HD-50017).
NOTE
Do not install sensors that have dropped or have been impacted by other components. Damage to the sensing
element can occur.
Replacement sensor assemblies have threads coated with ANTI-SEIZE LUBRICANT and new gaskets.
If reusing HO2S (Heated oxygen sensor), replace the gasket. Use a high-quality professional grade side cutter for
gasket removal. Make sure larger side of new gasket faces exhaust.
If reusing HO2S, apply a thin coat of ANTI-SEIZE LUBRICANT to each oxygen sensor.
1. See Figure 1 or Figure 2. Install HO2S (2). Tighten.
Torque: 16.3-19 N·m (12-14 ft-lbs) HO2S (Heated
oxygen sensor)
2. Connect HO2S connector (1).
1
HO2S connector
2
HO2S
Figure 1. Front HO2S (Heated Oxygen Sensor)
1
HO2S connector
2
HO2S
Figure 2. Rear HO2S (Heated Oxygen Sensor)
1. Install right side cover. See Remove.
2. Install main fuse. See Main Fuse.
1. Remove exhaust shields as necessary. See Prepare.
Muffler
1. See Muffler or Single Muffler. Remove muffler.
a. Discard clamp (4).
b. Remove screws (1).
c. Remove muffler (2).
d. Discard muffler gasket (3), if equipped.
End Cap
1. See Muffler End Cap. Remove end cap.
a.
Remove screws (1).
b.
Remove end cap (2).
Consumables
Description
Part Number
Size
ANTI-SEIZE LUBRICANT
98960-97
29.6 ml (1 fl oz)
Muffler
1.
NOTE
Use a pipe expander (such as Snap-on Part No.
PH300) on mufflers (2) to aid installation of gaskets
(3), if necessary.
See Figure 1 or Figure 2. Install new gasket into
muffler, if removed.
2. Install muffler.
a. Loosely install new clamp (4).
b. Align muffler with bracket.
c. Install screws (1). Hand-tighten.
d. Tighten screws.
Torque: 13.5-16.3 N·m (119-144 in-lbs) Muffler
screws
e. Tighten clamp.
Torque: 51.5-58.3 N·m (38-43 ft-lbs) Muffler clamp
End Cap
1. See Figure 3. Install end cap.
a. Apply anti-seize lubricant to screws (1).
ANTI-SEIZE LUBRICANT (98960-97)
b. Install end cap (2).
c. Install screws. Tighten.
Torque: 8.8-10.8 N·m (78-96 in-lbs) Muffler end
cap screws
1
Screw (2)
2
Muffler
3
Gasket
4
Clamp
Figure 1. Muffler
1
Screw (2)
2
Muffler
3
Gasket
4
Clamp
Figure 2. Single Muffler
1
Screw (3)
2
Muffler end cap
Figure 3. Muffler End Cap
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