Harley Davidson Softail 2000-2005. Service manual — page 22

270

CHAPTER SEVEN

20

erly. If necessary, adjust the throttle cables as described in
Chapter Three.
11. Install the air filter backplate and air filter as de-
scribed in this chapter.
12. Install the fuel tank as described in this chapter.
13. Start the engine and allow it to idle. Check for fuel
leaks.
14. Turn the handlebar from side to side. The idle speed
should remain the same. If the idle speed increases while
the handlebars are turned, the cables are installed incor-
rectly or are damaged. Remove the fuel tank and inspect
the cables.

Disassembly

Refer to Figure 20.

1. Unscrew and remove the starting enrichment valve
and cable (Figure 21).
2. Remove the screw and washer (A, Figure 22) on the
side and the top screw (A, Figure 23) securing the throttle
cable bracket to the carburetor. Remove the bracket (B,
Figure 23).
3. Remove the collar (Figure 24) from the cover.
4. Remove the remaining cover screws (Figure 25). Re-
move the cover and spring (A, Figure 26).

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

271

7

CARBURETOR

1. Screw
2. Cover
3. Collar
4. Spring
5. Spring seat
6. Jet needle
7. Vacuum piston
8. Cable sealing cap
9. Cable guide

10. Starting enrichment cap
11. Spring
12. Starting enrichment valve
13. Hose clamp
14. Spring
15. Hose
16. Fuel inlet fitting
17. Body
18. Screw
19. Spring
20. Screw
21. Throttle cable bracket
22. Screw and washer
23. Collar
24. Pin
25. Washer
26. Pilot jet
27. Float pivot pin
28. Needle jet
29. Main jet holder
30. Main jet
31. Valve
32. Float
33. Rod
34. Washer
35. Spring
36. Collar
37. Washer
38. E-clip
39. Pin
40. Washer
41. Lever
42. Rod
43. Boot
44. O-ring gasket
45. Float bowl
46. Screw
47. Diaphragm
48. Spring
49. O-ring
50. Cover
51. Washer
52. Screw

21

22

5. Remove the vacuum piston (B, Figure 26) from the
carburetor housing. Do not damage the jet needle extend-
ing out of the bottom of the vacuum piston.

6. Remove the float bowl as follows:

a. Remove the screws (Figure 27) securing the float

bowl to the carburetor.

b. Slowly remove the float bowl body and withdraw

the pump rod (Figure 28) from the boot on the
bowl.

c. Disconnect the pump rod from the lever assembly

on the carburetor (Figure 29).

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23

24

25

26

27

28

29

CAUTION

One of the float pin pedestals has an inter-
ference fit that holds the float pin in place.
An arrow, (

Figure 30

) cast into the carbure-

tor, points to this pedestal. To remove the
float pin, tap it out from the interference side
in the direction of the arrow. If the float pin
is removed opposite of the arrow, the oppo-
site pedestal may crack or break off. If this
occurs, the carburetor must be replaced.

7. Carefully tap the float pin (Figure 31) out of the pedes-
tals and remove it.
8. Remove the float and needle valve assembly (Figure 32).
9. Unscrew and remove the pilot jet (Figure 33).
10. Unscrew and remove the main jet (Figure 34).
11. Unscrew and remove the needle jet holder (Figure 35).
12. Remove the needle jet (A, Figure 36) from the needle
jet bore in the carburetor.

Cleaning and Inspection

Replace worn or damaged parts as described in this sec-

tion.

CAUTION

The carburetor body is equipped with plas-
tic parts that cannot be removed. Do not dip

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

273

7

30

31

32

33

34

35

the carburetor body, O-rings, float assembly,
needle valve or vacuum piston in a carburetor
cleaner or another harsh solution that can
damage these parts. The use of a caustic car-
buretor cleaning solvent is not recommended.
Instead, clean the carburetor and related
parts in a petroleum based solvent, or Simple
Green. Then rinse them in clean water.

1. Initially clean all parts in a mild petroleum based
cleaning solution. Then clean them in hot, soapy water
and rinse with cold water. Blow them dry with com-
pressed air.

CAUTION

If compressed air is not available, allow the
parts to air dry or use a clean, lint-free cloth.
Do

not

use a paper towel to dry carburetor

parts, as small paper particles may plug
openings in the carburetor housing or jets.

2. Allow the carburetors to dry thoroughly before assem-
bly. 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 alter the air/fuel
mixture.

3. Inspect the float bowl O-ring gasket (A, Figure 37) for
hardness or deterioration.
4. Inspect the accelerator pump boot (B, Figure 37) for
hardness or deterioration.
5. Make sure the accelerator pump cover (Figure 38)
screws are tight.
6. Inspect the vacuum piston diaphragm (Figure 39) for
cracks or deterioration. Check the vacuum piston sides
(Figure 40) for excessive wear. Install the vacuum piston
into the carburetor body and move it up and down in the
bore. The vacuum piston should move smoothly with no

274

CHAPTER SEVEN

36

37

38

39

40

binding or excessive play. If there is excessive play, the
vacuum piston slide and/or carburetor body must be re-
placed.
7. Inspect the needle valve tapered end for steps, uneven
wear or other damage (Figure 41).
8. Inspect the needle valve seat (B, Figure 36) for steps,
uneven wear or other damage. Insert the needle valve and
slowly move it back and forth to check for smooth opera-
tion. If either part is worn or damaged, replace both parts
as a pair for maximum performance.
9. Inspect the needle jet holder, pilot jet and main jet
(Figure 42). 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
43) for deterioration or damage.
11. Inspect the jet needle tapered end for steps, uneven
wear or other damage.
12. Inspect the float (Figure 44) for deterioration or dam-
age. 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 ap-
pear, there is a leak and the float must be replaced.
13. Make sure the throttle plate (Figure 45) screws are
tight. Tighten them if necessary.
14. Move the throttle wheel (Figure 46) back and forth
from stop to stop and check for free movement. The throt-

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

275

7

41

42

43

44

45

46

Damaged

Good

tle lever should move smoothly and return under spring
tension.

15. Check the throttle wheel return spring (Figure 47) for
free movement. Make sure it rotates the throttle wheel
back to the stop position with no hesitation.

16. Make sure all openings in the carburetor housing are
clear. Clean them out if they are plugged, then apply com-
pressed air to all openings.

17. Inspect the carburetor body for internal or external
damage. If there is damage, replace the carburetor assem-
bly, as the body cannot be replaced separately.

18. Check the top cover for cracks or damage.

19. Check the starting enrichment valve and cable as fol-
lows:

a. Check the end of the valve (Figure 48) for damage.

b. Check the entire length of the cable for bends,

chaffing or other damage.

c. Check the knob, nut and lockwasher for damage.

Move the knob and check for ease of movement.

Assembly

NOTE

The needle jet has two different sides and
must be installed as described in Step 1.

1. Position the needle jet with the long end going in first
(Figure 49) and install it (A, Figure 36).

2. Install the needle jet holder (Figure 35) into the main
jet passage. Make sure it passes through the opening in the
venturi (Figure 50), then tighten it securely.

3. Install the main jet and tighten it securely (Figure 34).

4. Install the pilot jet and tighten it securely (Figure 33).

5. Install the fuel valve onto the float (Figure 51) and po-
sition the float onto the carburetor so the valve drops into
its seat.

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47

48

49

50

51

CAUTION

The pedestals that support the float pin are
fragile. In the next step, support the pedestal
on the arrow side while tapping the float pin
into place.

6. Align the float pin with the two pedestals.
7. Install the float pin (A, Figure 52) from the side oppo-
site the arrow (B). Support the pedestal 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, Figure 37)

and accelerator rod boot (B) are in place.

b. Connect the pump rod to the lever assembly on the

carburetor (Figure 53).

c. Slowly install the float bowl body and insert the ac-

celerator pump rod through the boot (Figure 28) on
the float bowl. Engage the rod with the diaphragm
while installing the float bowl.

d. Install the float bowl and screws (Figure 27).

Tighten the screws securely in a crisscross pattern.

10. Insert the jet needle (Figure 54) through the center
hole in the vacuum piston.
11. Install the spring seat (A, Figure 55) and spring (B)
over the top of the needle to secure it in place.
12. Align the slides (A, Figure 56) on the vacuum piston
with the grooves (B) in the carburetor bore and install the
vacuum piston (B, Figure 26). 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 diaphragm
into the piston chamber groove (Figure 57).
14. Align the free end of the spring with the carburetor
top and install the top onto the carburetor.
15. Hold the carburetor top in place and lift the vacuum
piston with a finger (Figure 58). The piston should move
smoothly. If the piston movement is rough or sluggish, the

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

277

7

52

53

54

56

55

spring is installed incorrectly. Remove the carburetor top
and reinstall the spring.
16. Install the carburetor top screws (Figure 25) fin-
ger-tight.
17. Install the collar (Figure 24) into the cover.
18. Install the throttle cable bracket (B, Figure 23) onto
the carburetor so the end of the idle speed screw engages
the top of the throttle cam stop (B, Figure 22). Hold the
bracket in place and install the bracket’s side mounting
screw and washer (A, Figure 22). Tighten the screw se-
curely.
19. Install the top screw (A, Figure 23) and tighten it se-
curely.
20. Install the starting enrichment cable and valve into
the carburetor body. Tighten the nut securely (Figure 21).

Float Adjustment

The carburetor must be removed and partially disas-

sembled for this adjustment.
1. Remove the carburetor as described in this chapter.
2. Remove the float bowl as described in this chapter.
3. Place the engine manifold side of the carburetor on a
clean, flat surface as shown in Figure 59. This is the base
position.

278

CHAPTER SEVEN

57

58

59

60

61

FLOAT BASE POSITION

Carburetor

Float

FLOAT ADJUSTMENT

POSITION

Carburetor

Float

0.413-0.453 in.
(10.5-11.5 mm)

15

!

to 20

!

4. Tilt the carburetor upward 15-20

!

as shown in Figure

60. In this position, the float will come to rest without
compressing the pin return spring.

NOTE

If the carburetor is tilted less than 15° or
more than 20°, the float measurement will
be incorrect.

5. Measure from the carburetor flange surface to the top
of the float as shown in Figure 60. When measuring float
level, do not compress the float. The correct float level
measurement is 0.413-0.453 in. (10.5-11.5 mm).
6. If the float level is incorrect, remove the float pin and
float as described under

Carburetor Disassembly

in this

chapter.
7. Slowly bend the float tang (Figure 61) with a screw-
driver and adjust it to the correct position.
8. Reinstall the float and the float pin as described under

Carburetor Assembly

in this chapter. Recheck the float

level.
9. Repeat Steps 4-8 until the float level is correct.

10. Install the float bowl and carburetor as described in
this chapter.

INTAKE MANIFOLD (CARBURETED MODELS)

Removal/Installation

Refer to Figure 62.

1. Remove the carburetor as described in this chapter.

NOTE

The front and rear intake manifold flanges
are different. If the flanges are not marked,
label them with an F and R so they will be
reinstalled in the correct location.

2. Disconnect the electrical connector from the MAP sen-
sor (A, Figure 63) on top of the intake manifold.

NOTE

Figure 63

shows only two of the Allen bolts.

Remove all four bolts.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

279

7

62

INTAKE MANIFOLD (CARBURETED MODELS)

1. Manifold seal
2. Flange
3. Intake manifold
4. Screw
5. Clip
6. MAP sensor
7. Seal
8. Bolt
9. Seal ring

3. Remove the four Allen bolts (B, Figure 63) securing
the intake manifold to the cylinder heads.

4. Remove the intake manifold, flanges and manifold
seals.

5. Inspect the intake manifold as described in this section.

6. Install the flanges (A, Figure 64) and manifold seals
(B) onto the intake manifold.

7. Install the intake manifold onto the cylinder head in-
take ports.

8. Make sure 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 (Figure 65) into
the intake manifold.

CAUTION

Do not attempt to align the intake manifold
after tightening the bolts. This will damage
the manifold seals. If necessary, loosen the
bolts, then align the manifold.

11. Make sure the intake manifold seats squarely against
the cylinder heads. Then make sure the carburetor seats
squarely in the intake manifold. Remove the carburetor.

NOTE

It is very difficult to get an Allen wrench and
torque wrench onto the two inboard Allen
bolts to tighten them to a specific torque value.
Tighten the outboard Allen bolts to the speci-
fied torque value, then tighten the inboard Al-
len bolts to the same approximate tightness.

12. Tighten the intake manifold Allen bolts to 97-141
in.-lb. (11-16 N•m).

13. If the MAP sensor was removed, install a

new

seal in

the manifold receptacle, then install the MAP sensor.

14. Connect the electrical connector onto the MAP sen-
sor (A, Figure 63).

15. Install the carburetor as described in this chapter.

Inspection

1. Check the intake manifold seals (B, Figure 64) for
wear, deterioration or other damage. Replace the seals as a
set if necessary.

2. Check the intake manifold seal ring (C, Figure 64) for
cracks, flat spots or other damage. Replace it if necessary.

3. If necessary, remove the self-tapping screw and clamp,
and remove the MAP sensor.

ELECTRONIC FUEL INJECTION (EFI)

This section describes the components and operation of

the sequential port electronic fuel injection (EFI) system.
The advantages of a map controlled fuel and ignition sys-
tem working together are tremendous. It allows for the
elimination of an inefficient cold start enrichment devise
and allows for accurate control of the idle speed. Without
a carburetor there is no need for periodic adjustments and
altitude compensation is automatic. Improved torque
characteristics are achieved, while at the same time allow-
ing for greater fuel economy and low exhaust emissions
due to the matching of the air/fuel ratio and ignition point,
dependent upon load conditions. Engine performance
modification is possible by simply installing an electronic
control module (ECM) with different map characteristics.

Complete

service

of

the

system

requires

a

Harley-Davidson Scanalyzer and a number of other spe-
cialty tools. However, basic troubleshooting diagnosis is
no different on a fuel-injected machine than on a
carbureted one. If the check engine light comes on or there
is a drivability problem, make sure all electrical connec-
tions are clean and secure. A high or erratic idle speed may
indicate a vacuum leak. Make sure there is an adequate
supply of fresh gasoline. If basic tests fail to reveal the

280

CHAPTER SEVEN

63

64

cause of a problem, refer service to a Harley-Davidson
dealership. Incorrectly performed diagnostic procedures
can result in damage to the fuel injection system.

Electronic Control Module (ECM) and Sensors

The electronic control module (ECM) (Figure 66),

mounted under the seat, determines the optimum fuel in-
jection and ignition timing based on input from six or
seven sensors. The sensors (Figure 67 and Figure 68) and
their locations and functions are as follows:

1. The throttle position sensor (TP), located on the front
of the induction module and attached directly to the throt-
tle shaft, indicates throttle angle. The ECM determines the
air volume entering the engine based on the throttle angle.

2. The crankshaft position sensor (CKP), located on the
forward position of the left crankcase, is an inductive type
sensor. The ECM determines the engine speed by how fast
the machined teeth on the flywheel pass by the sensor.

NOTE

The 2001-on models are not equipped with
the camshaft position sensor.

3. The camshaft position (CMP), on 2000 models only,
located in the camshaft cover, is also an inductive sensor.
The ECM determines the camshaft position when the
semicircular ridge on the rear cylinder’s primary camshaft
chain sprocket passes the sensor.
4. The engine temperature sensor (ET) on 2001-on mod-
els, is located on the front cylinder head. The ECM adjusts
the injector opening time based on input from this sensor.
5. The intake air temperature sensor (IAT) is located in-
side the induction module (rear cylinder’s intake runner).
The ECM determines the air density and adjusts the injec-
tor opening time based on input from this sensor.
6. The manifold absolute pressure sensor (MAP) is lo-
cated on top of the intake module. The MAP monitors in-
take manifold pressure (vacuum) and sends this
information to the ECM.
7. The idle air control (IAC) valve is located on top of the
induction module. The ECM control the engine speed by
moving the IAC to open or close the passage around the
throttle plate.
8. The bank angle sensor (BAS), located within the turn
signal module (TSM) or the turn signal security module
(TSSM), interrupts the ignition and shuts off the engine if
the motorcycle’s lean angle is greater than 45

°

from verti-

cal for more than one second.

Make sure the ECM is securely mounted on the rubber

isolators to prevent damage from vibration. Do not tamper
with the ECM; it is sealed to prevent moisture contamina-
tion.

Fuel Supply System

Fuel pump and filters

The fuel pump and filter assembly is located inside the

fuel tank. This assembly is part of the removable canopy
attached to the top of the fuel tank. The canopy provides
easy removal and installation of the attached components
without having to work within the fuel tank cavity. An in-
let screen on the fuel pump and the secondary fuel filter
canister are located downstream from the fuel pump to
provide maximum filtration before the fuel reaches the
fuel injectors.

Fuel line

The fuel line is attached to the base of the fuel tank with

quick-disconnect fittings.

The fuel supply line pressure is 58 psi (400 kPa). A

check valve is located on the fuel line where it attaches to
the fuel tank.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

281

7

66

65

Fuel injectors

The solenoid-actuated constant-stroke pintle-type fuel

injectors consist of a solenoid plunger, needle valve and
housing. The fuel injector’s opening is fixed and fuel
pressure is constant.

The ECM controls the time the injectors open and close.

Induction Module

The induction module (Figure 68) consists of the two

fuel injectors, fuel pressure regulator, throttle position
sensor, intake air temperature sensor, idle speed lever, fuel
supply line fitting and the idle speed control actuator.

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CHAPTER SEVEN

67

ENGINE SENSORS

1. Screw
2. Clamp
3. MAP sensor
4. Seal
5. Engine temperature sensor (ET)

(2001-on fuel-injected models)

6. O-ring
7. Crankshaft position sensor (CKP)

(2001-on)

8. Screw
9. Screw*

10. Washer*
11. Camshaft position sensor (CMP)*
12. O-ring*
13. Clamp
14. Screw
15. Oil pressure switch
16. Anchor connector
17. Anchor connector

*Camshaft position sensor

on 2000 models only.

DEPRESSURIZING THE FUEL SYSTEM

(EFI MODELS)

The fuel system is under pressure at all times, even

when the engine is not operating. The system must be
depressurized prior to loosening fittings or disconnecting
fuel lines within the fuel injection system. Gasoline will
spurt out unless the system is depressurized.

1. Remove the seat as described in Chapter Fourteen.

2. At the rear of fuel tank, disconnect the fuel pump sin-
gle-pin black electrical connector (Figure 69).

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

283

7

68

69

INDUCTION MODULE

1. Throttle position sensor (TP)
2. Purge tube fitting

(California models only)

3. Intake air temperature sensor (IAT)
4. Manifold absolute pressure sensor (MAP)

5. Fuel injector (front cylinder)
6. Idle air control valve (IAC)
7. Throttle cable bracket
8. Fuel injector (rear cylinder)

REAR

FRONT

3. Start the engine and allow it to idle until it runs out of
gasoline.

4. After the engine has stopped, operate the starter for
three seconds to eliminate any residual gasoline in the fuel
lines.

5. After all service procedures have been completed, con-
nect the fuel pump single-pin black electrical connector
(Figure 69).

6. Install the seat.

INDUCTION MODULE

(EFI MODELS)

Removal

Refer to Figure 70.

1. Remove the fuel tank as described in this chapter.

2. Remove the air filter assembly as described in this
chapter.

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CHAPTER SEVEN

70

INDUCTION MODULE

1. Screw
2. Fuel supply line
3. Washer
4. Gasket
5. Mounting bracket
6. Fuel rail
7. Mounting bracket
8. Fuel injector
9. Manifold air pressure sensor (MAP)

10. Induction module
11. Screw
12. Flange
13. Gasket
14. Bolt
15. Pin
16. Cable bracket
17. Idle air control valve (IAC)
18. Gasket
19. O-ring seal
20. Screw
21. Intake air temperature sensor (IAT)
22. Gasket
23. Throttle position sensor (TP)
24. Throttle housing

3. On California models, disconnect the EVAP hose from
the port on the induction module. Plug the end of the hose
to keep out debris.

4.

Carefully

disconnect the electrical connector from

each fuel injector by rocking the connector back and forth.

5. Disconnect the following electrical connectors from
the induction module:

a. Intake air temperature sensor (IAT) (A, Figure 71).

b. Idle air control valve (IAC) (B, Figure 71).

c. Manifold pressure sensor (MAP).

d. Throttle position sensor (TP) (Figure 72).

e. Fuel injectors.

6. Disconnect the throttle cables from the induction mod-
ule as described in this chapter.

NOTE

The front and rear intake manifold flanges
are different. If the flanges are not marked,
label them with an F and R so they will be
reinstalled in the correct locations.

NOTE

The type of bolts securing the induction
module differs with the various years. Some
models are equipped with hex-head bolts
while others are fitted with Allen bolts. On
models equipped with Allen bolts, use a 1/4
inch ball Allen bit with a 4 in. extension.

7. Working on the right side of the motorcycle, loosen
and remove the lower two bolts (Figure 73) securing the
cylinder head mounting flanges to the cylinder heads.
Loosen, but do not remove, the upper two Allen bolts se-
curing the cylinder head mounting flanges to the cylinder
heads.

8. Working on the left side of the motorcycle, loosen and
remove the lower two bolts (Figure 74) securing the cyl-
inder head mounting flanges to the cylinder heads.
Loosen, but do not remove, the upper two Allen bolts se-
curing the cylinder head mounting flanges to the cylinder
heads.

9. Slide the induction module part way out of the cylinder
head ports past the upper bolts.

10. Depress the button (A, Figure 75) on the fuel line fit-
ting. Disconnect the fuel line and fitting (B, Figure 75)
from the induction module fitting (C) and remove the in-
duction module.

11. Remove the mounting flanges and discard the seals.

12. Inspect the induction module and fuel hoses as de-
scribed in this section.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

285

7

71

72

73

74