Harley Davidson 2018 softail models. Service manual — page 21
Remove
1. See Figure 1. Detach console.
a. Remove front screw (1).
b. Remove rear screw (4)
c. Move console (2) rearward.
2. See Figure 2. Disconnect connector.
a. Remove grommet (4) from backbone (1).
b. Pull harness (2) from backbone.
NOTE
See the electrical diagnostic manual for the appropriate disassembly procedure for the connector.
c. Disconnect connector (3).
3. Remove console.
Install
1. See Figure 2. Connect connector.
a. Connect connector (3).
b. Feed harness (2) into backbone (1).
c. Position grommet (4) into backbone.
2. See Figure 1. Install console.
a. Align console (2) with bracket (3).
b. Install front screw (1).
c. Install rear screw (4).
d. Tighten front screw.
Torque: 3.4-5.6 N·m (30-50 in-lbs) Console screw
(Front)
e. Tighten rear screw.
Torque: 2.8-3.4 N·m (25-30 in-lbs) Console screw
(Rear)
1
Front screw
2
Console
3
Bracket
4
Rear screw
Figure 1. Console
1
Backbone
2
Harness
3
Connector
4
Grommet
Figure 2. Console Harness
Remove
1. See Figure 1. Detach console.
a. Remove screws (1).
b. Move console (2) rearward.
2. See Figure 2. Disconnect connector.
a. Remove grommet (4) from backbone (1).
b. Pull harness (2) from backbone.
NOTE
See the electrical diagnostic manual for the appropriate disassembly procedure for the connector.
c. Disconnect connector (3).
Install
1. See Figure 2. Connect connector.
a. Connect connector (3).
b. Feed harness (2) into backbone (1).
c. Seat grommet (4) into backbone.
2. See Figure 1. Install console.
a. Align console (2) with bracket (3).
b. Install screws (1). Tighten.
Torque: 4.5-5.6 N·m (40-50 in-lbs) Console
screws
1
Screw (2)
2
Console
3
Bracket
Figure 1. Console
1
Backbone
2
Harness
3
Connector
4
Grommet
Figure 2. Console Harness
1. All but FXFB, FXFBS Install Seat. See Remove.
2. Install main fuse. See Main Fuse.
1. See Decorative Fuel Cap. Remove decorative fuel cap from mounting bracket.
a. Press down and turn decorative fuel cap (1) counterclockwise.
b. Remove decorative fuel cap from mounting bracket (3).
2. See Bracket Orientation. Mark location of mounting bracket with masking tape.
NOTE
Wear protective gloves.
3. Remove mounting bracket.
a. Saw behind mounting bracket with mono-filament fishing line or waxed dental floss to separate bracket from
fuel tank.
NOTE
For maximum bond, mounting surface must be clean and dry.
4. Clean mounting surface on fuel tank.
a. Use 3M GENERAL PURPOSE ADHESIVE REMOVER to remove remaining foam backing tape and
adhesive from mounting surface.
b. Clean the mounting surface with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water.
5. If reusing mounting bracket: Clean bracket mounting surface.
a. Use 3M GENERAL PURPOSE ADHESIVE REMOVER to remove remaining foam backing tape and
adhesive from mounting bracket.
b. Clean the mounting surface with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water.
NOTE
Apply mounting bracket within minutes of cleaning to prevent possible surface contamination.
NOTE
Apply in ambient temperatures between 21-38 °C (70-100 °F)
Do not remove protective film from adhesive until ready to apply.
1. If reusing mounting bracket: See Figure 1. Apply adhesive (3) to back of mounting bracket (2).
2. See Figure 2. Test fit mounting bracket to ensure proper orientation.
NOTE
Protect adhesive from grease, oil, dust, dirt and finger prints.
Once applied, do not shift bracket.
The adhesive bonds in 72 hours at room temperature.
3. Install mounting bracket.
a. Remove protective film from back of adhesive.
b. Apply even pressure across entire surface of mounting bracket. Hold in place for 15 seconds.
NOTE
Wait 20 mins before touching mounting bracket.
Wait 24 hours before washing.
4. See Figure 1. Install decorative fuel cap (1) to mounting bracket.
a. Align locking lugs on decorative fuel cap with locking fingers on mounting bracket. Turn cap clockwise to
lock into position.
1
Decorative fuel cap
2
Bracket
3
Adhesive
Figure 1. Decorative Fuel Cap
Figure 2. Bracket Orientation
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.
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)
2. Purge fuel system. See Prepare.
Special Tools
Description
Part Number
Qty.
FUEL PRESSURE GAUGE
HD-41182
1
1. See Figure 1. Attach valve union (2) on FUEL PRESSURE GAUGE (Part Number:HD-41182) to schrader valve
(4) on fuel line (3).
2. Close fuel valve (1).
3. Insert clear tube of fuel pressure gauge into a suitable container.
4. Start engine.
5. Open fuel valve.
6. Open clear tube bleeder valve to remove air from fuel pressure tester.
7. Close clear tube bleeder valve.
8. Operate engine at various speeds. Note pressure gauge reading. Compare readings to specifications. Fuel Pump
Specifications.
9. Turn off engine.
10. Open clear tube bleeder to remove pressure from fuel pressure gauge.
11. Remove fuel pressure tester.
1
Fuel valve (closed position)
2
Valve union
3
Fuel line
4
Schrader valve
Figure 1. Fuel Pressure Test
1. Secure fuel tank. See Prepare.
2. Install seat. See Remove.
1. Remove seat. See Remove.
1. See Fuel Tank. Lift rear of fuel tank.
a. Loosen front fuel tank mounting screw (5).
b. Remove rear fuel tank mounting screw (1), washers (2), and acorn nut (3).
NOTE
Verify fuel tank or fuel tank console do not contact any components when lifting.
c. Lift rear of fuel tank.
1. See Fuel Pump Connector. Disconnect fuel pump connector.
a. Disconnect fuel pump connector.
2. Purge fuel line.
a. Start engine.
b. Allow vehicle to stall.
c. Operate starter for 3 seconds to remove any remaining fuel.
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. See Figure 2. Connect fuel pump connector.
2. See Figure 1. Install rear fuel tank mounting screw (1),
washers (2), and acorn nut (3). Tighten.
Torque: 38-43.4 N·m (28-32 ft-lbs) Fuel tank mounting
screw
3. Tighten front fuel tank mounting screw (5) and acorn nut.
Torque: 38-43.4 N·m (28-32 ft-lbs) Fuel tank mounting
screw
1
Rear fuel tank mounting screw
2
Washer (4)
3
Acorn nut (2)
4
Bushing and grommet (4)
5
Front fuel tank mounting screw
6
Filler neck ring
Figure 1. Fuel Tank
Figure 2. Fuel Pump Connector
1. Install seat. 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)
1. Remove seat. See Remove.
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)
2. Purge fuel system. See Prepare.
3. Remove main fuse. See Main Fuse.
4. Remove air cleaner. See Remove.
5. Remove air cleaner backplate assembly. See Prepare.
Remove
1. See Fuel Line to Fuel Tank Disconnect fuel line from fuel tank.
a. Push up on sleeve of quick disconnect fitting (1).
b. Remove fuel line (2) from quick disconnect fitting.
2. See Fuel Line to Fuel Rail Disconnect fuel line from fuel rail.
a. Remove screw (2).
b. Pull fuel line (1) away from fuel rail (3).
c. Inspect O-ring (4) for damage. replace as necessary.
1. See Figure 1. Install fuel line to fuel rail.
a. Install new O-ring (4) to fuel line (1), if removed.
b. Connect fuel line to fuel rail (3).
c. Install screw (2). Tighten.
Torque: 2.5-4.5 N·m (22-40 in-lbs) Fuel line to fuel
rail screw
2. See Figure 2 Install fuel line to fuel tank.
a. Press up on sleeve of quick disconnect fitting (1).
b. Connect fuel line (2) to quick disconnect fitting.
c. Release sleeve of quick disconnect fitting to secure
fuel line.
1
Fuel line
2
Screw
3
Fuel rail
4
O-ring
Figure 1. Fuel Line to Fuel Rail
1
Quick disconnect fitting
2
Fuel line
Figure 2. Fuel Line to Fuel Tank
1. Secure fuel tank. See Prepare.
2. Install seat. See Remove.
3. Install air cleaner backplate assembly. See Prepare.
4. Install air cleaner. See Remove.
5. Install main fuse. See Main Fuse.
6. Set OFF/RUN switch to RUN and check for leaks.
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.
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)
4. Disconnect fuel line at quick disconnect fitting. See Prepare.
5. Disconnect vent line. See Prepare.
6. Drain fuel tank.
7. If equipped with fuel tank console:
a. disconnect fuel tank console connector. See Prepare.
b. If necessary remove console. See Prepare.
1. See Fuel Tank. Remove fuel tank.
a. Remove front fuel tank mounting screw (5), washers (2), and acorn nut (3).
b. Remove fuel tank.
c. Remove bushings and grommets (4) if necessary.
NOTE
Vent screws in fuel tank are for manufacturing purposes and not intended to be removed.
1. See Figure 1. Install fuel tank.
a. Install bushings and grommets (4) if removed.
b. Place fuel tank onto frame backbone.
c. Loosely install front fuel tank mounting screw (5), washers (2), and acorn nut (3).
NOTE
Filler neck ring (6) is a functional part which must remain in position for proper fuel system operation.
1
Rear fuel tank mounting screw
2
Washer (4)
3
Acorn nut (2)
4
Bushing and grommet (4)
5
Front fuel tank mounting screw
6
Filler neck ring
Figure 1. Fuel Tank
NOTE
Vent screws are not meant to be removed. If removed for any reason, replace with new screws.
1. See Figure 2. Install new screws. Tighten.
Torque: 9.5-12.2 N·m (84-108 in-lbs) Fuel tank vent
screws
Figure 2. Vent Screws
1. Secure fuel tank. See Prepare.
2. If equipped with fuel tank console:
a. If necessary install console. See Prepare.
b. Connect console connector. See Prepare.
3. Connect vent line. See Prepare.
4. Connect fuel line at quick disconnect fitting. See Prepare.
5. Install seat. See Remove.
6. Install main fuse. See Main Fuse.
7. Set OFF/RUN switch to RUN and check for leaks.
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.
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)
4. Remove fuel tank. See Prepare.
NOTE
Fuel pumps used in 5 gallon fuel tanks are equipped with a flexible siphon tube (6).
1. See Fuel Pump. Remove fuel pump assembly.
a. Remove screws (1).
b. Using a wooden tool, pull inlet strainer (3) from fuel tank.
c. Remove fuel pump assembly (5).
2. Discard seal (4).
WARNING
Do not use solvents or other products that contain chlorine on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss of fuel system pressure or engine stalling and could result in
death or serious injury. (00621b)
1. See Fuel Pump. Clean and inspect fuel pump assembly.
a. Inspect fuel pickup screen (3) for damage. Replace if
necessary.
b. Clean fuel pump assembly (5).
2.
NOTE
Placing o-ring in wrong groove will hinder fuel system
venting.
3.5 gal tank pumps: See Figure 1. Inspect o-ring (2) on
vent tube (1) and verify proper location.
1
Vent tube
2
O-ring
Figure 1. Vent Tube O-ring Location
1. See Figure 1. Install new seal (4).
2.
NOTE
Fuel pumps used in 5 gallon fuel tanks are
equipped with a flexible siphon tube (6), siphon
tube must be routed to opposite side of fuel tank
during fuel pump installation.
Do not bend float rod of fuel level sender. A bent
float rod results in incorrect gauge readings.
Install fuel pump assembly.
a. Insert siphon tube into fuel tank, if equipped.
b. Insert fuel level sender float (2) into fuel tank.
c. Insert fuel pump assembly (5) half way into fuel tank.
d. Insert inlet strainer (3) into fuel tank.
e. Install fuel pump assembly.
f. Install screws (1).
3. See Figure 2. Tighten in sequence shown.
Torque: 4.5-5 N·m (40-45 in-lbs) Fuel pump assembly
screws
1
Screw (5)
2
Fuel level sender float
3
Inlet strainer
4
Seal
5
Fuel pump assembly
6
Siphon tube
Figure 1. Fuel Pump
Figure 2. Tightening Sequence
Level Sender
1. See Level Sender. Remove level sender.
a. Disconnect electrical connector (4).
b. Press tab (1) to release level sender bracket (2).
c. Remove level sender (3).
Pressure Regulator
1. See Pressure Regulator. Remove regulator cover.
a. Remove regulator cover retaining clip (4).
b. Remove regulator cover (1).
2. Discard pressure regulator (2) and adapter with O-ring (3).
NOTE
Plastic portion of pressure regulator may separate from assembly during removal, if this occurs plastic portion
must be removed before installing new pressure regulator.
Filter
1. Remove regulator cover.
2. See Fuel Filter. Remove filter housing.
a. Remove retaining clip (3).
b. Remove filter housing (2) from filter base (5).
3. Remove and discard fuel filter (4).
4. Remove and discard O-ring (6).
Pump
1. Remove level sender.
2. See Fuel Pump. Remove pump retainer.
a. Press tabs (3) to release pump retainer (2).
b. Remove pump retainer.
3. Disconnect electrical connectors (1).
4. See Fuel Pump and Inlet Strainer. Remove pump (4).
5. Remove lower isolator (1).
6. If necessary remove and discard inlet strainer (5).
7. Inspect parts for damage. Replace if necessary.
1. pump
2. spacer (3)
3. O-ring (2)
Inlet Strainer
1. See Fuel Pump and Inlet Strainer. Remove pump (4).
2. Remove and discard inlet strainer (5).
Level Sender
1. See Figure 1 Install level sender.
a. Align level sender bracket (2) with tab (1).
b. Install level sender (3).
c. Connect electrical connector (4).
Pressure Regulator
1. See Figure 2 Install new pressure regulator (2) and adapter with O-ring (3).
2. Install regulator cover.
a. Install regulator cover (1).
b. Install regulator cover retaining clip (4).
Filter
1. See Figure 3 Install new filter (4).
2. Install new O-ring (6).
3. Install filter housing.
a. Install filter housing (2) onto filter base (5) and bracket (1).
b. Install filter housing retaining clip (3).
4. Install regulator cover.
Pump
1. See Figure 5 If necessary install new inlet strainer (5).
2. Install fuel pump spacer (3) and, O-ring (2).
3. Install lower isolator (1).
4. Install pump (4).
5. See Figure 4 Connect electrical connectors (1).
6. Install pump retainer (2).
7. Install level sender.
Inlet Strainer
1. See Figure 5 Install new inlet strainer (5) in proper orientation.
2. Install pump (4).
1
Tab
2
Level sender bracket
3
Level sender
4
Electrical connector
Figure 1. Level Sender
1
Regulator cover
2
Pressure regulator
3
Adapter with O-ring
4
Retaining clip
Figure 2. Pressure Regulator
1
Bracket
2
Filter housing
3
Retaining clip
4
Fuel filter
5
Filter base
6
O-ring
Figure 3. Fuel Filter
1
Electrical connector (2)
2
Pump retainer
3
Tab (4)
Figure 4. Fuel Pump
1
Lower isolator
2
O-ring
3
Spacer
4
Pump
5
Inlet strainer
Figure 5. Fuel Pump and Inlet Strainer
1. Install fuel tank. See Prepare.
2. Install seat. See Remove.
3. Install main fuse. See Main Fuse.
NOTE
Add at least 3.8 L (1 gal) of fuel to fuel tank before operating fuel pump.
4. Set OFF/RUN switch to RUN and check for leaks.
1. Remove seat. See Remove.
2. Remove left side cover. SeeRemove.
3. Remove main fuse. See Main Fuse.
NOTE
Right side cover, battery and tray removal are only necessary if replacing lower vent line.
4. Remove right side cover. See Remove.
5. Remove battery. See Prepare.
6. Remove battery tray. See Prepare.
1. See Fuel Tank Vent Line. Remove upper vent line.
a. Remove and discard cable strap (1).
b. Disconnect upper vent line (2) from vapor valve (3).
c. Disconnect upper vent line from fuel tank.
d. Remove upper vent line.
2. Remove lower vent line.
a. Disconnect lower vent line (4) from vapor valve.
b. Remove lower vent line.
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