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SPECIFICATIONS 9.1

EFI FUSES TORQUE VALUES

Fuel Pump 15 Blue Blade
Item ft/in-lbs Nm
ECM Power 15 Blue Blade
Battery hold-down clamp
15-20 ft-lbs 20-27 Nm
TORX bolt
Battery cable bolt 60-96 in-lbs 6.8-10.9 Nm

EFI System
ECM socket screws 50-60 in-lbs 5.7-6.8 Nm
Relay Electrical bracket flange
Spare 36-48 in-lbs 4.1-5.4 Nm
nuts
Crank position
Fuel Pump
90-120 in-lbs 10.2-13.6 Nm
sensor screw
Engine sensor harness
25-35 in-lbs 2.8-4.0 Nm
clip screws to crankcase

ECM Power
Engine temperature
120-180 in-lbs 13.6-20.3 Nm
sensor
f2223x9x
Fuel tank rear mounting
15-20 ft-lbs 20-27 Nm
bolt
Fuel tank front mounting
Figure 9-1. EFI Fuses (Under Right Side Cover) 15-20 ft-lbs 20-27 Nm
bolts
Fuel tank canopy TORX
18-24 in-lbs 2.0-2.7 Nm
screws
Fuel level sender TORX
25-35 in-lbs 2.8-4.0 Nm
screw
Fuel supply line
22-26 ft-lbs 29.8-35.3 Nm
quick-connect fitting
Fairing lower U-bolt
35-40 in-lbs 4.0-4.5 Nm
retainer locknuts
Fairing lower cap screws 10-15 in-lbs 1.1-1.7 Nm
Intake manifold to throttle
27-33 in-lbs 3.1-3.7 Nm
body TORX screws
Intake flange adapter
96-144 in-lbs 10.9-16.3 Nm
screws
Exhaust flange adapter
60-80 in-lbs 6.8-9.0 Nm
screws
Fuel rail TORX screws 27-33 in-lbs 3.0-3.7 Nm
Fuel supply tube clamp
27-33 in-lbs 3.0-3.7 Nm
TORX screw
Intake air temperature
12 in-lbs 1.4 Nm
sensor TORX screws
Throttle position sensor
27-33 in-lbs 3.0-3.7 Nm
TORX screws
Throttle cable bracket
27-33 in-lbs 3.0-3.7 Nm
side TORX screw
Idle air control flange
25 in-lbs 2.8 Nm
screws
Console mounting bolt
50-90 in-lbs 5.7-10.2 Nm
acorn nut

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NOTES

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ELECTRICAL BRACKET ASSEMBLY 9.2

GENERAL DATA LINK CONNECTOR

See Figure 9-2. The electrical bracket assembly is mounted

beneath the side cover on the right side of the vehicle. The SETTING ENGINE IDLE SPEED
electrical bracket assembly carries the following components:
NOTE
● Data Link Connector Engine idle speed can only be set using DIGITAL TECHNI-
CIAN (Part No. HD-44750). Do not tamper with the throttle
● Main Harness to EFI Harness Connector
stop screw as it will not permanently change idle speed.
● ECM Power Fuse/Fuel Pump Fuse
1. Turn the ignition/light key switch to OFF.
● EFI System Relay
2. Remove right side saddlebag. See Section 2.25 SAD-
● Electronic Control Module (ECM) DLEBAG, REMOVAL.
● Vehicle Speed Sensor Connector
3. Gently pull side cover from frame downtubes (no tools
● Optional Security Siren Connector required).

2
1

6,7

3
4

f1917x9x

1. Data Link Connector [91]

2. Main Harness Connector [8] 5. Electronic Control Module (ECM)
3. Fuse Block (ECM Power Fuse, Fuel Pump 6. Vehicle Speed Sensor Connector [65]
Fuse, EFI System Relay) (Under Bracket)
4. Electronic Control Module Connector [78] 7. P&A Security Siren Connector [142] (Under Bracket)

Figure 9-2. Electrical Bracket Assembly

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INSTALLATION
EFI System Relay 1. Install relay in slots of fuse block. See Figure 9-3.
Spare 2. Engage tabs on fuse block with slots in bracket. Slide
fuse block up into cavity. Gently tug on conduit to verify
that fuse block is locked in place.
3. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
Fuel required).
Pump 4. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
f2223x9x

ECM Power
EFI FUSES

REMOVAL
Figure 9-3. EFI Fuse Block
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
4. Gently pull on data link connector [91] to disengage from
required).
arms on electrical bracket. See Figure 9-2.
3. Locate painted white dot on inboard side of fuse block.
5. Remove rubber protective plug from data link connector. Pressing on dot, gently tug on conduit to release tabs on
6. See DIGITAL TECHNICIAN (Part No. HD-44750) or the fuse block from slots in bracket.
2004 ELECTRICAL DIAGNOSTIC MANUAL (Part No. 4. Pull fuses from slots in fuse block and inspect for dam-
99497-04) to use the data link connector for system age. Replace fuse if the element is burned or broken.
diagnosis and electrical troubleshooting. Automotive type ATO fuses are used. See Figure 9-3.
7. Install protective plug in data link connector. NOTE
While a spare 15 amp fuse is located in the EFI fuse block,
8. With the plug side down and in contact with tab, position
one extra 10 amp and 15 amp fuse are also located in the
connector between arms on electrical bracket.
system fuse block cover. See Section 8.3 SYSTEM FUSES
9. Align barbed studs in side cover with grommets in frame for more information.
downtubes and push firmly into place (no tools
required).
INSTALLATION
10. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION. 1. Insert fuse in the appropriate slot. See Figure 9-3.
2. Engage tabs on fuse block with slots in bracket. Slide
fuse block up into cavity. Gently tug on conduit to verify
that fuse block is locked in place.
EFI SYSTEM RELAY 3. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
REMOVAL 4. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required). ELECTRONIC CONTROL MODULE
3. Locate painted white dot on inboard side of fuse block.
Pressing on dot, gently tug on conduit to release tabs on REMOVAL
fuse block from slots in bracket.
1. Remove right side saddlebag. See Section 2.25 SAD-
4. Pull relay from slots in fuse block. See Figure 9-3. DLEBAG, REMOVAL.

9-4 2004 Touring: Fuel Injection

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2. Gently pull side cover from frame downtubes (no tools

required). f2183x8x

3. Depress external latch and use rocking motion to

remove ECM connector [78]. See Figure 9-2.
4. Remove two socket screws to detach ECM from electri-
cal bracket.
1
INSTALLATION
1. Align holes in ECM with those in electrical bracket.
Install two socket screws and tighten to 50-60 in-lbs
(5.7-6.8 Nm). See Figure 9-2.
2. Install ECM connector [78]. Push connector halves
together until latch clicks.
3. Align barbed studs in side cover with grommets in frame
2
downtubes and push firmly into place (no tools
required).
1. Vehicle Speed Sensor [65]
4. Install right side saddlebag. See Section 2.25 SADDLE-
2. P&A Security Siren [142]
BAG, INSTALLATION.

Figure 9-4. Electrical Bracket (Inboard Side)

SECURITY SIREN CONNECTOR

EFI HARNESS
REMOVAL
For removal and installation instructions, see Section 8.32
1. Remove right side saddlebag. See Section 2.25 SAD- WIRING HARNESSES AND CABLES, EFI HARNESS
DLEBAG, REMOVAL. (FUEL INJECTED).

2. Gently pull side cover from frame downtubes (no tools

required).
3. Remove two flange nuts to release electrical bracket
from studs on side of battery box. See Figure 9-4.

INSTALLATION
1. Install security siren connector [142] and vehicle speed
sensor connector [65] on inboard side of electrical
bracket as shown in Figure 9-4. Be sure that conduit and
cables are properly routed or wires may be pinched dur-
ing installation.
2. Slide electrical bracket onto studs at side of battery box.
3. Install flange nuts on studs and tighten to 36-48 in-lbs
(4.1-5.4 Nm).
4. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
5. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.

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SENSORS 9.3

GENERAL f2256x8x

Six sensors inform the ECM of the environmental and engine

operating factors influencing fuel and spark requirements.
The sensors are as follows:

● Intake Air Temperature Sensor

● Throttle Position Sensor
● Manifold Absolute Pressure Sensor
● Bank Angle Sensor (Internal to TSM/TSSM)
● Crankshaft Position Sensor
● Engine Temperature Sensor

Stator
INTAKE AIR TEMPERATURE SENSOR Connector [46]

See Section 9.5 INDUCTION MODULE ASSEMBLY, Crankshaft

INTAKE AIR TEMPERATURE SENSOR. Position Sensor
Connector [79]
THROTTLE POSITION SENSOR
Figure 9-5. Voltage Regulator (Left Side View)
See Section 9.5 INDUCTION MODULE ASSEMBLY,
THROTTLE POSITION SENSOR.
f2217x8x

MANIFOLD ABSOLUTE PRESSURE Socket Screw

SENSOR
See Section 9.5 INDUCTION MODULE ASSEMBLY, MANI-
FOLD ABSOLUTE PRESSURE SENSOR.

BANK ANGLE SENSOR

See Section 8.17 TURN SIGNAL/SECURITY MODULE.

CRANKSHAFT POSITION SENSOR

REMOVAL
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL. Figure 9-6. Remove Sensor Mount Socket Screw
2. Locate crankshaft position sensor connector [79], 2-
place Mini-Deutsch, fixed to bracket at bottom of voltage
regulator. See Figure 9-5.
5. Remove allen head socket screw to free crankshaft posi-
3. Push connector toward right side of motorcycle to disen- tion sensor mount from front left side of crankcase. Pull
gage small end of slot on attachment clip from T-stud on sensor from bore. See Figure 9-6.
bracket. Lift connector off T-stud. 6. Pull sensor to draw convoluted tubing and connector out
4. Depress button on socket terminal side and pull apart from under voltage regulator.
pin and socket halves. 7. Remove terminals from pin housing. See Figure 9-7.

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7. Place large end of slot on attachment clip over T-stud on
bracket. Push connector toward left side of motorcycle to
Convoluted engage small end of slot.
Tubing 8. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.

O-Ring
ENGINE TEMPERATURE SENSOR

f2218x8x
REMOVAL
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
Figure 9-7. Crankshaft Position Sensor
MAXI-FUSE, REMOVAL.
2. On left side of motorcycle, pull back boot at back of front
NOTE cylinder to reveal engine temperature sensor connector
For instructions on properly removing wire terminals, see [90], 2-place Packard.
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING PINS. 3. Pull external latch outward and use rocking motion to
remove connector.
8. Remove convoluted tubing from crankshaft position sen- 4. Slide a 3/4 inch deepwell socket over the sensor body
sor cable. hex and turn counter-clockwise to loosen. See Figure 9-
8. When sensor turns easily, pull out the deepwell socket
and remove sensor by hand.
INSTALLATION
1. Install convoluted tubing onto crankshaft position sensor
INSTALLATION
cable. See Figure 9-7.

2. Referencing the following table, install terminals into pin 1. Hand start threaded end of new temperature sensor into
housing. cylinder head bore.
2. Slide 3/4 inch deepwell socket over sensor body hex and
Table 9-1. Crankshaft Position Sensor [79] tighten to 120-180 in-lbs (13.6-20.3 Nm).
3. Install engine temperature sensor connector [90], 2-
Wire Color Chamber Number
place Packard, at back of front cylinder.
Red 1
4. Pull boot over sensor to keep out dirt and debris.
Black 2
5. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
NOTE
For instructions on properly installing wire terminals, see
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING PINS. Sensor
Thermistor Body Hex
3. Install new O-ring in groove on sensor body. Apply a thin
film of clean H-D 20W50 engine oil to O-ring before
installation.

4. Push sensor into bore aligning hole in sensor mount with

hole in spot face. Install allen head socket screw and
tighten to 90-120 in-lbs (10.2-13.6 Nm). See Figure 9-6.

5. Route connector and convoluted tubing under front

engine stabilizer link to underside of voltage regulator.
f1699x9x

6. Mate pin and socket halves of crankshaft position sensor

connector [79]. See Figure 9-5. Figure 9-8. Engine Temperature Sensor

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FUEL TANK (FUEL INJECTED) 9.4

GENERAL ● Fuel Level Sender

● Low Fuel Level Warning Lamp
See Figure 9-9. The fuel pump, fuel filter canister, fuel pres- ● Fuel Supply Check Valve
sure regulator, and fuel level sender are attached to the can-
opy for easy removal and installation. The act of raising the
canopy automatically removes these items, thereby eliminat-
ing those tasks which used to be performed by reaching
inside the fuel tank. This arrangement minimizes the possibil- COMPLETE REMOVAL
ity of dropping or losing parts inside the tank, or adding con-
taminants (such as grease and oil) to the fuel supply.
FLHT/C/U/I, FLTRI
The fuel tank assembly consists of the following components:

● Fuel Tank 1WARNING

● Canopy
Gasoline is extremely flammable and highly explosive.
● Fuel Pump When servicing the fuel system, do not smoke or allow
● Fuel Pressure Regulator open flame or sparks in the vicinity. Inadequate safety
● Fuel Filter Canister precautions could result in death or serious injury.

Canopy
Fuel Filter
Canister
Fuel Level
Sender Fuel Pressure
and Float Regulator

In-tank Tubing
(Fuel Pressure Regulator
to Supply Fitting)

Fuel Pump

In-tank Tubing
Supply Fitting (Fuel Pump to Filter Canister)
f1969x9x
(Check Valve)

Figure 9-9. Fuel Tank Assembly (FLHT/C/U/I, FLTRI)

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a. Remove the 15 amp fuel pump fuse. See Figure 9-
10. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 sec-
onds to remove remaining fuel from fuel lines.

Fuel 1WARNING
Pump
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.

4. Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.
f2223x9x
5. Carefully cut anchored cable strap securing main har-
Figure 9-10. EFI Fuse Block ness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
1WARNING 6. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws secure
Gasoline will drain from the crossover hose when dis- console to clip nuts on the canopy bracket.
connected from the fuel tank. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable 7. Remove Allen head screw to detach flange at rear of
manner. Gasoline is extremely flammable and highly console from clip nut on fuel tank weldment.
explosive. Inadequate safety precautions could result in 8. Lay a clean shop towel on forward part of rear fender.
death or serious injury.
9. Remove filler cap from neck of fuel tank. Remove con-
sole and lay upside down on shop towel. Reinstall filler
CAUTION cap.
10. Depress button on socket side and remove fuel level
Do not kink crossover hose or crimp shut using pliers or
sender/fuel pump connector [141], 3-place Mini-Deut-
similar tool. Damage to the rigid inner lining will occur.
sch, at top of canopy.
1. Drain fuel tank as follows: 11. Gently pry fuel vapor vent tube from fitting on filler neck
Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D. of fuel tank. Exercise caution to avoid pulling fitting from
Insert bolt in one end of hose and install hose clamp to filler neck.
ensure that end is securely plugged. Using a side cutters, cut
clamp from one end of crossover hose beneath fuel tank. 1WARNING
Quickly replace crossover hose on fuel tank fitting with open
end of short hose while directing flow of gasoline from free A small amount of gasoline may drain from the fuel sup-
end of crossover hose into suitable container. ply line when disconnected from the fuel tank. Thor-
oughly wipe up any spilled fuel immediately. Dispose of
2. Remove seat. See Section 2.24 SEAT, REMOVAL. rags in a suitable manner. Gasoline is extremely flamma-
ble and highly explosive. Inadequate safety precautions
1WARNING could result in death or serious injury.

The gasoline in the fuel supply line downstream of the

fuel pump is under high pressure (58 psi). To avoid an
1WARNING
uncontrolled discharge or spray of gasoline, always Exercise caution to avoid twisting the fuel supply line fit-
purge the system of high pressure gas before the fuel ting, as any cracks in the plastic construction of the line
supply line is disconnected. Gasoline is extremely flam- can result in gas leaks. Gas leakage can cause fire or
mable and highly explosive. Inadequate safety precau- explosion which could result in death or serious injury.
tions could result in death or serious injury.
12. Locate quick-connect fitting on left side of fuel tank. Pull
3. Purge the fuel supply line of high pressure gas. Proceed up on chrome sleeve and pull down on fuel supply line
as follows: fitting to disconnect. See Figure 9-11.

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f2021x9x
Fuel CAUTION
Tank
When removing instrument console, exercise caution to
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
6. Secure instrument console to top of rear fender using
Chrome bungee cords.
Sleeve
7. Remove console mounting bolt from slot at top of can-
opy.
8. Gently pry fuel vapor vent tube from fitting.
9. At bottom left side of fuel tank, gently pull on convoluted
tubing to draw fuel gauge connector [117], 4-place Mul-
tilock, out of tunnel. Depress button on socket terminal
side and pull apart pin and socket halves.

1WARNING
Figure 9-11. Fuel Supply Line Fitting
A small amount of gasoline may drain from the fuel sup-
ply line when disconnected from the fuel tank. Thor-
13. Remove two fuel tank front mounting bolts (with flat oughly wipe up any spilled fuel immediately. Dispose of
washers) from left and right side of frame. Remove bolt rags in a suitable manner. Gasoline is extremely flamma-
(with flat washer) to free rear of fuel tank from frame ble and highly explosive. Inadequate safety precautions
backbone. could result in death or serious injury.

NOTE
The fuel tank mounting bolts have both an internal TORX
1WARNING
recess and an external hex, which allows them to be Exercise caution to avoid twisting the fuel supply line fit-
removed with either a T40 TORX bit or a 1/2 inch open end/ ting, as any cracks in the plastic construction of the line
box wrench. Use of the external hex allows the front mount- can result in gas leaks. Gas leakage can cause fire or
ing bolts to be removed without having to loosen or remove explosion which could result in death or serious injury.
the fairing lowers, if installed.
10. Locate quick-connect fitting on left side of fuel tank. Pull
14. Remove fuel tank from vehicle. up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
11. Remove fuel tank from vehicle.
FLHR/C/S/I
1. See Section 9.4 FUEL TANK (FUEL INJECTED), COM- INSTALLATION
PLETE REMOVAL, FLHT/C/U/I, FLTRI, steps 1-4.
(AFTER COMPLETE REMOVAL)
2. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame FLHT/C/U/I, FLTRI
backbone. On FLHRSI models, removal of rear bolt also
releases instrument console bracket.
CAUTION
3. Carefully cut anchored cable strap securing main har-
ness bundle, instrument console conduit, and fuel vapor Exercise caution to avoid pinching the wiring harness
vent tube to left side of frame backbone. between the fuel tank and vehicle frame. Wire damage
may result in electrical problems.
4. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent 1. Work fuel tank into position aligning front flange holes
on FLHRSI models). with those in frame.
5. Raise instrument console and bend back flexible clamp 2. Slide new clamp onto free end of crossover hose. Run-
on canopy to release main harness conduit. Depress ning hose beneath frame backbone, install hose onto fit-
button on socket side and remove fuel level sender/fuel ting at bottom front of fuel tank (after removing
pump connector [141], 3-place Mini-Deutsch. temporary plug). Crimp clamp.

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3. Start fuel tank front mounting bolts (with flat washers)

f2007x9x into left and right side of frame.
Console 4. Install bolt (with flat washer) to secure rear of fuel tank to
Pod frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).
Fuel
Tank 5. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-
27 Nm).

Fuel Pump, 1WARNING

Fuel Level
Sender Conduit Exercise caution to avoid twisting the fuel supply line fit-
ting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.

Main Fuel 6. Locate quick-connect fitting on left side of fuel tank. Pull
Harness Fuel Vapor Overflow up on chrome sleeve and insert neck of fuel supply line
Bundle Vent Tube Hose fitting. While pushing up on bottom of fitting, pull down
(To Vapor Valve) on chrome sleeve until it “clicks” into the locked position.

1WARNING
Main To avoid an uncontrolled discharge or spray of gasoline,
Anchored
Console Cable Strap Harness always be sure the quick-connect fitting is properly
Pod Conduit Bundle mated. A slight tug on the fuel supply line fitting will ver-
ify this condition. Gasoline is extremely flammable and
FLHTCUI highly explosive. Inadequate safety precautions could
result in death or serious injury.

7. Connect fuel vapor vent tube to nipple on filler neck of

f1739b9x
fuel tank.

Fuel 8. Install fuel level sender/fuel pump connector [141], 3-

Tank place Mini-Deutsch, at top of canopy.
Console 9. Remove filler cap. Position console on canopy. Route
cables from beneath console as shown in Figure 9-12.
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
Fuel Pump,
Fuel Level 10. Install Allen head screw to fasten rear flange of console
Sender Conduit to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
11. Open fuel door on console. Install two Allen head screws
Fuel to secure front of console to clip nuts on canopy bracket.
Overflow Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
Fuel Vapor Hose
Vent Tube 12. Snap anchor of new cable strap into hole on left side of
(To Vapor Valve) frame backbone. Tighten cable strap capturing main har-
ness bundles, console pod conduit (Ultra models only),
Main fuel level sender/fuel pump conduit, and fuel vapor vent
Harness tube. See Figure 9-12. Cut any excess cable strap mate-
Bundle rial.
Anchored Main
Cable Strap Harness NOTE
Bundle
Route fuel overflow hose inboard of wire bundles on right
side of frame, but do not capture in cable straps.
FLHT/C/I, FLTRI
13. Insert bolt through battery negative cable (black) into
Figure 9-12. Console Pod Cable/Hose Routing threaded hole of battery negative (-) terminal. Tighten
(Top View) bolt to 60-96 in-lbs (6.8-10.9 Nm).

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14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
Convoluted
15. Install seat. See Section 2.24 SEAT, INSTALLATION. Tubing

FLHR/C/S/I
1. Work fuel tank into position aligning front flange holes
with those in frame.

2. Slide new clamp onto free end of crossover hose. Run-

ning hose beneath frame backbone, install hose onto fit- 8870
ting at bottom front of fuel tank (after removing
temporary plug). Crimp clamp.
Figure 9-13. Fuel Gauge (FLHR/C/S)

1WARNING
11. Install acorn nut at top of instrument console and tighten
Exercise caution to avoid twisting the fuel supply line fit- to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
ting, as any cracks in the plastic construction of the line Phillips screw and large flat washer (absent on FLHRSI
can result in gas leaks. Gas leakage can cause fire or models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
explosion which could result in death or serious injury.
12. Connect fuel gauge to main harness. Route pin housing
3. Locate quick-connect fitting on left side of fuel tank. Pull and convoluted tubing forward and then inboard
up on chrome sleeve and insert neck of fuel supply line between front of crossover hose fitting and bottom of fuel
fitting. While pushing up on bottom of fitting, pull down tank. Mate pin and socket halves of fuel gauge connec-
on chrome sleeve until it “clicks” into the locked position. tor [117], 4-place Multilock. Feed connector into tunnel
of fuel tank. See Figure 9-13.

1WARNING 13. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
To avoid an uncontrolled discharge or spray of gasoline, ness bundle, instrument console conduit, and fuel vapor
always be sure the quick-connect fitting is properly vent tube. Cut any excess cable strap material. See Fig-
mated. A slight tug on the fuel supply line fitting will ver- ure 9-12.
ify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could 14. Insert bolt through battery negative cable (black) into
result in death or serious injury. threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
4. Connect fuel vapor vent tube to fitting at top of canopy. 15. Install the 15 amp fuel pump fuse. See Figure 9-10. If
5. Slide head of console mounting bolt into slot at top of necessary, see Section 9.2 ELECTRICAL BRACKET
canopy. ASSEMBLY, EFI FUSES, INSTALLATION.
16. Install seat. See Section 2.24 SEAT, INSTALLATION.
6. Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3-
place Mini-Deutsch, at top of canopy. Bend flexible
clamp to capture main harness conduit. PARTIAL REMOVAL
7. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
FLHT/C/U/I, FLTRI
8. Start fuel tank front mounting bolts (with flat washers)
into left and right side of frame.

9. Install bolt (with flat washer) to secure rear of fuel tank to

1WARNING
frame backbone. On FLHRSI models, capture instru- Gasoline is extremely flammable and highly explosive.
ment console bracket during installation. Tighten bolt to When servicing the fuel system, do not smoke or allow
15-20 ft-lbs (20-27 Nm). open flame or sparks in the vicinity. Inadequate safety
precautions could result in death or serious injury.
10. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-
27 Nm). 1. Remove seat. See Section 2.24 SEAT, REMOVAL.

9-12 2004 Touring: Fuel Injection

HOME

1WARNING 1WARNING
The gasoline in the fuel supply line downstream of the Exercise caution to avoid twisting the fuel supply line fit-
fuel pump is under high pressure (58 psi). To avoid an ting, as any cracks in the plastic construction of the line
uncontrolled discharge or spray of gasoline, always can result in gas leaks. Gas leakage can cause fire or
purge the system of high pressure gas before the fuel explosion which could result in death or serious injury.
supply line is disconnected. Inadequate safety precau-
tions could result in death or serious injury. 11. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
2. Purge the fuel supply line of high pressure gas. Proceed fitting to disconnect. See Figure 9-11.
as follows: 12. Remove two fuel tank front mounting bolts (with flat
a. Remove the 15 amp fuel pump fuse. See Figure 9- washers) from left and right side of frame. Remove bolt
10. If necessary, see Section 9.2 ELECTRICAL (with flat washer) to free rear of fuel tank from frame
BRACKET ASSEMBLY, EFI FUSES, REMOVAL. backbone.
b. Start the engine and allow the vehicle to run. NOTE
c. When the engine stalls, operate starter for 3 sec- The fuel tank mounting bolts have both an internal TORX
onds to remove remaining fuel from fuel lines. recess and an external hex, which allows them to be
removed with either a T40 TORX bit or a 1/2 inch open end/
box wrench. Use of the external hex allows the front mount-
1WARNING ing bolts to be removed without having to loosen or remove
To protect against shock and accidental start-up of vehi- the fairing lowers, if installed.
cle, disconnect the negative battery cable before pro- 13. Raise the fuel tank approximately 2 inches. Move the
ceeding. Inadequate safety precautions could result in fuel tank crossover hose to the rear of the ignition coil,
death or serious injury. so that the tank can be raised an additional 2-3 inches.
3. Unthread bolt and remove battery negative cable (black) Move fuel tank straight back and rest on frame back-
from battery negative (-) terminal. bone.

4. Carefully cut anchored cable strap securing main har- 14. Obtain several 1 x 2 inch wooden blocks. Raise front and
ness bundles, console pod conduit (Ultra models only), rear of fuel tank off the frame backbone by placing
fuel level sender/fuel pump conduit, and fuel vapor vent blocks in tunnel at bottom of tank.
tube to left side of frame backbone.
5. Open fuel door on console. Remove two Allen head FLHR/C/S/I
screws inboard of rubber bumpers. These screws secure
console to clip nuts on the canopy bracket. 1. See Section 9.4 FUEL TANK (FUEL INJECTED), PAR-
TIAL REMOVAL, FLHT/C/U/I, FLTRI, steps 1-3.
6. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment. 2. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
7. Lay a clean shop towel on forward part of rear fender. (with flat washer) to free rear of fuel tank from frame
8. Remove filler cap from neck of fuel tank. Remove con- backbone. On FLHRSI models, removal of rear bolt also
sole and lay upside down on shop towel. Reinstall filler releases instrument console bracket.
cap. 3. Carefully cut anchored cable strap securing main har-
9. Depress button on socket side and remove fuel level ness bundle, instrument console conduit, and fuel vapor
sender/fuel pump connector [141], 3-place Mini-Deut- vent tube to left side of frame backbone.
sch, at top of canopy. 4. Remove acorn nut from instrument console. If present,
10. Gently pry fuel vapor vent tube from fitting on filler neck also remove Phillips screw and large flat washer (absent
of fuel tank. Exercise caution to avoid pulling fitting from on FLHRSI models).
filler neck. 5. Raise instrument console and bend back flexible clamp
on canopy to release main harness conduit. Depress
1WARNING button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
A small amount of gasoline may drain from the fuel sup-
ply line when disconnected from the fuel tank. Thor- CAUTION
oughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flamma- When removing instrument console, exercise caution to
ble and highly explosive. Inadequate safety precautions avoid damaging speedometer unit. Wrap console in a
could result in death or serious injury. clean, dry shop towel to prevent damage.

2004 Touring: Fuel Injection 9-13

HOME

6. Secure instrument console to top of rear fender using

bungee cords. 1WARNING
7. Remove console mounting bolt from slot at top of can- Exercise caution to avoid twisting the fuel supply line fit-
opy. ting, as any cracks in the plastic construction of the line
8. Gently pry fuel vapor vent tube from fitting at top of can- can result in gas leaks. Gas leakage can cause fire or
opy. explosion which could result in death or serious injury.
9. At bottom left side of fuel tank, gently pull on convoluted
tubing to draw fuel gauge connector [117], 4-place Mul- 5. Locate quick-connect fitting on left side of fuel tank. Pull
tilock, out of tunnel. Depress button on socket terminal up on chrome sleeve and insert neck of fuel supply line
side and pull apart pin and socket halves. See Figure 9- fitting. While pushing up on bottom of fitting, pull down
13. on chrome sleeve until it “clicks” into the locked position.

1WARNING 1WARNING
A small amount of gasoline may drain from the fuel sup- To avoid an uncontrolled discharge or spray of gasoline,
ply line when disconnected from the fuel tank. Thor- always be sure the quick-connect fitting is properly
oughly wipe up any spilled fuel immediately. Dispose of mated. A slight tug on the fuel supply line fitting will ver-
rags in a suitable manner. Gasoline is extremely flamma- ify this condition. Gasoline is extremely flammable and
ble and highly explosive. Inadequate safety precautions highly explosive. Inadequate safety precautions could
could result in death or serious injury. result in death or serious injury.

1WARNING 6. Connect fuel vapor vent tube to fitting on filler neck of

fuel tank.
Exercise caution to avoid twisting the fuel supply line fit-
7. Install fuel level sender/fuel pump connector [141], 3-
ting, as any cracks in the plastic construction of the line
place Mini-Deutsch, at top of canopy.
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury. 8. Remove filler cap. Position console on canopy. Route
10. Locate quick-connect fitting on left side of fuel tank. Pull cables from beneath console as shown in Figure 9-12.
up on chrome sleeve and pull down on fuel supply line Be sure that hoses and wires are not pinched by the
fitting to disconnect. See Figure 9-11. console during installation. Reinstall filler cap.

11. Raise the fuel tank approximately 2 inches. Move the 9. Install Allen head screw to fasten rear flange of console
fuel tank crossover hose to the rear of the ignition coil, to clip nut on fuel tank weldment. Tighten screw to 25-30
so that the tank can be raised an additional 2-3 inches. in-lbs (2.8-3.4 Nm).
Move fuel tank straight back and rest on frame back-
bone. 10. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
12. Obtain several 1 x 2 inch wooden blocks. Raise front and
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
rear of fuel tank off the frame backbone by placing
blocks in tunnel at bottom of tank. 11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
ness bundles, console pod conduit (Ultra models only),
INSTALLATION fuel level sender/fuel pump conduit, and fuel vapor vent
(AFTER PARTIAL REMOVAL) tube. Cut any excess cable strap material. See Figure 9-
12.
NOTE
FLHT/C/U/I, FLTRI
Route fuel overflow hose inboard of wire bundles on right
1. Remove wooden blocks and move fuel tank toward its side of frame, but do not capture in cable straps.
installed position. While positioning fuel tank, move
crossover hose in front of ignition coil. Work fuel tank 12. Insert bolt through battery negative cable (black) into
into position aligning front flange holes with those in threaded hole of battery negative (-) terminal. Tighten
frame. bolt to 60-96 in-lbs (6.8-10.9 Nm).
2. Start fuel tank front mounting bolts (with flat washers)
into left and right side of frame. 13. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
3. Install bolt (with flat washer) to secure rear of fuel tank to ASSEMBLY, EFI FUSES, INSTALLATION.
frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).
4. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20- 14. Install seat. See Section 2.24 SEAT, INSTALLATION.
27 Nm).

9-14 2004 Touring: Fuel Injection

HOME

FLHR/C/S/I 12. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
1. Remove wooden blocks and move fuel tank toward its ness bundle, instrument console conduit, and fuel vapor
installed position. While positioning fuel tank, move vent tube. Cut any excess cable strap material. See Fig-
crossover hose in front of ignition coil. Work fuel tank ure 9-12.
into position aligning front flange holes with those in
13. Insert bolt through battery negative cable (black) into
frame.
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
1WARNING 14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
Exercise caution to avoid twisting the fuel supply line fit- necessary, see Section 9.2 ELECTRICAL BRACKET
ting, as any cracks in the plastic construction of the line ASSEMBLY, EFI FUSES, INSTALLATION.
can result in gas leaks. Gas leakage can cause fire or 15. Install seat. See Section 2.24 SEAT, INSTALLATION.
explosion which could result in death or serious injury.

2. Locate quick-connect fitting on left side of fuel tank. Pull

up on chrome sleeve and insert neck of fuel supply line CONSOLE POD/CANOPY
fitting. While pushing up on bottom of fitting, pull down
on chrome sleeve until it “clicks” into the locked position.
FLHT/C/U/I, FLTRI
1WARNING
REMOVAL
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will ver- 1WARNING
ify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could Gasoline will drain from the crossover hose when dis-
result in death or serious injury. connected from the fuel tank. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable
3. Connect fuel vapor vent tube to fitting at top of canopy. manner. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
4. Slide head of console mounting bolt into slot at top of
death or serious injury.
canopy.
5. Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3- CAUTION
place Mini-Deutsch, at top of canopy. Bend flexible
Do not kink crossover hose or crimp shut using pliers or
clamp to capture main harness conduit.
similar tool. Damage to the rigid inner lining will occur.
6. Align hole in instrument console with console mounting
bolt and place into position on fuel tank. 1. Drain fuel tank as follows:

7. Start fuel tank front mounting bolts (with flat washers) Obtain a short section of hose with a 5/16 inch (7.9 mm)
into left and right side of frame. I.D. Insert bolt in one end of hose and install hose clamp
to ensure that end is securely plugged. Cut clamp from
8. Install bolt (with flat washer) to secure rear of fuel tank to one end of crossover hose beneath fuel tank. Quickly
frame backbone. On FLHRSI models, capture instru- replace crossover hose on fuel tank fitting with open end
ment console bracket during installation. Tighten bolt to of short hose while directing flow of gasoline from free
15-20 ft-lbs (20-27 Nm). end of crossover hose into suitable container.
9. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20- 2. Remove seat. See Section 2.24 SEAT, REMOVAL.
27 Nm).
10. Install acorn nut at top of instrument console and tighten 1WARNING
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRSI The gasoline in the fuel supply line downstream of the
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm). fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
11. Connect fuel gauge to main harness. Route pin housing purge the system of high pressure gas before the fuel
and convoluted tubing forward and then inboard supply line is disconnected. Inadequate safety precau-
between front of crossover hose fitting and bottom of fuel tions could result in death or serious injury.
tank. Mate pin and socket halves of fuel gauge connec-
tor [117], 4-place Multilock. Feed connector into tunnel 3. Purge the fuel supply line of high pressure gas. Proceed
of fuel tank. See Figure 9-13. as follows:

2004 Touring: Fuel Injection 9-15

HOME
11. Gently pry fuel vapor vent tube from fitting on filler neck
f1955x9x of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
12. Using a T20 TORX bit, remove ten screws around the
outer edge of the canopy. Discard screws.
13. Raise canopy slightly to access top fitting (inlet port) at
back of fuel pressure regulator. Using a side cutters, cut
hose clamp and remove convoluted tube. Exercise cau-
tion to avoid cutting or damaging tube or dropping
pieces of cut clamp into fuel tank. See Figure 9-14.
14. Remove canopy from fuel tank (with attached fuel pres-
sure regulator, fuel filter canister, fuel pump and fuel
level sender).
A spring-loaded hinge on the fuel pump bracket facili-
tates removal of the assembly. For best results, press
Convoluted down on top of fuel pump with index finger or end of
Tube screwdriver, and after raising canopy slightly, rotate on
hinge in a counterclockwise direction. When canopy is at
a 45˚ angle to top of fuel tank, carefully pull assembly
Figure 9-14. Raise Canopy and Remove Tube from left side lobe of fuel tank. See Figure 9-16.
(FLHT/C/U/I, FLTRI) 15. Remove and discard canopy gasket. Verify that sealing
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
a. Remove the 15 amp fuel pump fuse. See Figure 9-
10. If necessary, see Section 9.2 ELECTRICAL INSTALLATION
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
1. Obtain new canopy gasket. With the locator bump on the
b. Start the engine and allow the vehicle to run.
gasket OD toward the front, position gasket at bottom of
c. When the engine stalls, operate starter for 3 sec- canopy. Start four nubs on gasket into holes in canopy.
onds to remove remaining fuel from fuel lines. Moving to top of canopy, alternately grasp each nub and
pull through hole.
1WARNING
CAUTION
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro- Exercise care to avoid bending float rod of fuel level
ceeding. Inadequate safety precautions could result in sender during installation. Be sure to position float rod
death or serious injury. to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will
4. Unthread bolt and remove battery negative cable (black) result in erroneous gauge readings.
from battery negative (-) terminal.
2. While holding fuel pump stationary, raise canopy slightly
5. Carefully cut anchored cable strap securing main har- and rotate on hinge 90˚ in a counterclockwise direction.
ness bundle, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent 3. Holding assembly so that canopy is at a 45˚ angle to top
tube to left side of frame backbone. of fuel tank, insert assembly into left side lobe of fuel
tank. The spring-loaded hinge on the fuel pump bracket
6. Open fuel door on console. Remove two Allen head automatically returns assembly to its installed position
screws inboard of rubber bumpers. These screws secure inside fuel tank.
console to clip nuts on the canopy bracket.
7. Remove Allen head screw to detach flange at rear of CAUTION
console from clip nut on fuel tank weldment.
Carefully inspect end of convoluted tube for cuts, tears,
8. Lay a clean shop towel on forward part of rear fender.
holes or other damage. Replace tube if any damage is
9. Remove filler cap from neck of fuel tank. Remove con- found. Even the smallest hole can cause a reduction in
sole and lay upside down on shop towel. Reinstall filler fuel pressure.
cap.
4. Raise canopy slightly and slide new hose clamp onto
10. Depress button on socket side and remove fuel level free end of convoluted tube. Install tube onto top fitting
sender/fuel pump connector [141], 3-place Mini-Deut- (inlet port) at back of fuel pressure regulator. Crimp
sch, at top of canopy. clamp. See Figure 9-14.

9-16 2004 Touring: Fuel Injection

HOME
10. Open fuel door on console. Install two Allen head screws
Sealing to secure front of console to clip nuts on canopy bracket.
Device Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main har-
ness bundles, console pod conduit (Ultra models only),
f1963x9x fuel level sender/fuel pump conduit, and fuel vapor vent
tube. See Figure 9-12. Cut excess cable strap material.
1
12. Slide new clamp onto free end of crossover hose. Run-
7 9 ning hose beneath frame backbone, install hose onto fit-
ting at bottom front of fuel tank. Crimp clamp.
3 6
13. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
5 4 bolt to 60-96 in-lbs (6.8-10.9 Nm).

10 8
f1957x9x

f2011x9x 2

Figure 9-15. Canopy Sealing Screws and Torque

Sequence

1WARNING
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity
resulting in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.

NOTE
Check canopy screws for proper sealing devices. Screws
must have a bonded seal on underside of head. Replace f1956x9x
screws if seal is missing or damaged. See Figure 9-15.

5. While pushing down on the canopy, align holes in can-

opy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
Figure 9-15.
6. Connect fuel vapor vent tube to fitting on filler neck of
fuel tank.
7. Install fuel level sender/fuel pump connector [141], 3-
place Mini-Deutsch, at top of canopy.
8. Remove filler cap. Position console on canopy. Route
cables from beneath console as shown in Figure 9-12.
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
9. Install Allen head screw to fasten rear flange of console
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm). Figure 9-16. Remove Canopy From Vehicle (FLHR/C/S/I)

2004 Touring: Fuel Injection 9-17

HOME

14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET 1WARNING
ASSEMBLY, EFI FUSES, INSTALLATION.
To protect against shock and accidental start-up of vehi-
15. Install seat. See Section 2.24 SEAT, INSTALLATION. cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
4. Unthread bolt and remove battery negative cable (black)
INSTRUMENT CONSOLE/CANOPY from battery negative (-) terminal.
5. Carefully cut anchored cable strap securing main har-
FLHR/C/S/I ness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
REMOVAL 6. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRSI models).
1WARNING 7. On FLHRSI models only, remove bolt (with flat washer)
Gasoline will drain from the crossover hose when dis- to free rear of fuel tank from frame backbone. Removal
connected from the fuel tank. Thoroughly wipe up any of rear bolt also releases instrument console bracket.
spilled fuel immediately. Dispose of rags in a suitable 8. Raise instrument console and bend back flexible clamp
manner. Gasoline is extremely flammable and highly on canopy to release main harness conduit. Depress
explosive. Inadequate safety precautions could result in button on socket side and remove fuel level sender/fuel
death or serious injury. pump connector [141], 3-place Mini-Deutsch.

CAUTION CAUTION

Do not kink crossover hose or crimp shut using pliers or When removing instrument console, exercise caution to
similar tool. Damage to the rigid inner lining will occur. avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
1. Drain fuel tank as follows:
9. Secure instrument console to top of rear fender using
Obtain a short section of hose with a 5/16 inch (7.9 mm) bungee cords.
I.D. Insert bolt in one end of hose and install hose clamp
to ensure that end is securely plugged. Cut clamp from 10. Remove console mounting bolt from slot at top of can-
one end of crossover hose beneath fuel tank. Quickly opy.
replace crossover hose on fuel tank fitting with open end 11. Gently pry fuel vapor vent tube from fitting at top of can-
of short hose while directing flow of gasoline from free opy.
end of crossover hose into suitable container.
12. Using a T20 TORX bit, remove ten screws around the
2. Remove seat. See Section 2.24 SEAT, REMOVAL. outer edge of the canopy. Discard screws.
13. Raise canopy slightly to access top fitting (inlet port) at
1WARNING back of fuel pressure regulator. Using a side cutters, cut
hose clamp and remove convoluted tube. Exercise cau-
The gasoline in the fuel supply line downstream of the tion to avoid cutting or damaging tube or dropping
fuel pump is under high pressure (58 psi). To avoid an pieces of cut clamp into fuel tank. See Figure 9-14.
uncontrolled discharge or spray of gasoline, always
14. Remove canopy from fuel tank (with attached fuel pres-
purge the system of high pressure gas before the fuel
sure regulator, fuel filter canister, fuel pump and fuel
supply line is disconnected. Inadequate safety precau-
level sender).
tions could result in death or serious injury.
A spring-loaded hinge on the fuel pump bracket facili-
3. Purge the fuel supply line of high pressure gas. Proceed tates removal of the assembly. For best results, press
as follows: down on top of fuel pump with index finger or end of
a. Remove the 15 amp fuel pump fuse. See Figure 9- screwdriver, and after raising canopy slightly, rotate on
10. If necessary, see Section 9.2 ELECTRICAL hinge in a counterclockwise direction. When canopy is at
BRACKET ASSEMBLY, EFI FUSES, REMOVAL. a 45˚ angle to top of fuel tank, carefully pull assembly
from left side lobe of fuel tank. See Figure 9-16.
b. Start the engine and allow the vehicle to run.
15. Remove and discard canopy gasket. Verify that sealing
c. When the engine stalls, operate starter for 3 sec- devices from screws are not lodged in canopy holes.
onds to remove remaining fuel from fuel lines. Remove and discard devices if present.

9-18 2004 Touring: Fuel Injection

HOME

INSTALLATION 8. Moving instrument console toward installed position,

install fuel level sender/fuel pump connector [141], 3-
1. Obtain new canopy gasket. With the locator bump on the place Mini-Deutsch, at top of canopy. Bend flexible
gasket OD toward the front, position gasket at bottom of clamp to capture main harness conduit.
canopy. Start four nubs on gasket into holes in canopy. 9. Align hole in instrument console with console mounting
Moving to top of canopy, alternately grasp each nub and bolt and place into position on fuel tank.
pull through hole.
10. Install acorn nut at top of instrument console and tighten
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
CAUTION Phillips screw and large flat washer (absent on FLHRSI
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod 11. On FLHRSI models only, install bolt (with flat washer) to
to the right of the fuel gauge drain tube or it will be bent secure rear of fuel tank and instrument console bracket
during installation of the canopy. A bent float rod will to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
result in erroneous gauge readings. Nm).
12. Snap anchor of new cable strap into hole on left side of
2. While holding fuel pump stationary, raise canopy slightly
frame backbone. Tighten cable strap capturing main har-
and rotate on hinge 90˚ in a counterclockwise direction.
ness bundle, instrument console conduit, and fuel vapor
3. Holding assembly so that canopy is at a 45˚ angle to top vent tube. Cut any excess cable strap material.
of fuel tank, insert assembly into left side lobe of fuel 13. Slide new clamp onto free end of crossover hose. Run-
tank keeping the float rod positioned to the right of the ning hose beneath frame backbone, install hose onto fit-
fuel gauge drain tube. The spring-loaded hinge on the ting at bottom front of fuel tank. Crimp clamp.
fuel pump bracket automatically returns assembly to its
installed position inside fuel tank. 14. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
CAUTION
15. Install the 15 amp fuel pump fuse. See Figure 9-10. If
Carefully inspect end of convoluted tube for cuts, tears, necessary, see Section 9.2 ELECTRICAL BRACKET
holes or other damage. Replace tube if any damage is ASSEMBLY, EFI FUSES, INSTALLATION.
found. Even the smallest hole can cause a reduction in 16. Install seat. See Section 2.24 SEAT, INSTALLATION.
fuel pressure.

4. Raise canopy slightly and slide new hose clamp onto

free end of convoluted tube. Install tube onto top fitting
(inlet port) at back of fuel pressure regulator. Crimp FUEL FILTER CANISTER
clamp. See Figure 9-14.
Replace the fuel filter canister every 25,000 miles (40,000
km) . Proceed as follows:
1WARNING
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity
REMOVAL
resulting in gas leaks. Gas leakage can cause fire or 1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
explosion which could result in death or serious injury. REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
NOTE
2. Release fuel filter canister as follows:
Check canopy screws for proper sealing devices. Screws
must have a bonded seal on underside of head. Replace a. Pull wireform to release from slots on fuel filter can-
screws if seal is missing or damaged. See Figure 9-15. ister bracket. See A of Figure 9-17.
b. Use hinge to swing wireform out of the way. Move
5. While pushing down on the canopy, align holes in can-
canister bracket forward to disengage tab from slot
opy with those in fuel tank. Hand start ten new T20
on canopy weldment. See B of Figure 9-17.
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in c. Pull fitting on canister from fuel pressure regulator
Figure 9-15. assembly. See C of Figure 9-17.
6. Connect fuel vapor vent tube to fitting at top of canopy. 3. Using a side cutters, cut hose clamp and remove convo-
luted tube from inlet port at side of fuel filter canister.
7. Slide head of console mounting bolt into slot at top of Exercise caution to avoid cutting or damaging tube. Dis-
canopy. card fuel filter canister.

2004 Touring: Fuel Injection 9-19

HOME

INSTALLATION
A CAUTION

Do not replace tubes inside of fuel tank with ordinary

bulk hose. All internal lines must be replaced with the
special original equipment convoluted nylon tubes. Bulk
hose will degrade when immersed in gasoline (particu-
larly stale gasoline), resulting in contamination of the
fuel supply. Use of contaminated fuel will cause starting
and driveability problems and possible vehicle damage.

1. If present, remove and discard plastic caps from fittings

of new fuel filter canister.
2. Slide new hose clamp onto free end of convoluted tube
(from fuel pump). Install tube onto inlet port at side of
f1940x9x
fuel filter canister. If necessary, use a little isopropyl
alcohol or glass cleaner to aid installation. Crimp clamp.
Pull wireform from slots in canister bracket.
3. Install fuel filter canister as follows:
a. Install new O-ring onto fitting of fuel filter canister.
B Insert fitting into fuel pressure regulator assembly,
so that inlet port is on fuel pump side. See C of Fig-
ure 9-17.
b. Slide tab on canister bracket into slot of canopy
weldment until bump on bracket engages depres-
sion at side of canister. See B of Figure 9-17.
c. Use hinge to rotate wireform over canister bracket.
Press on wireform until it fully engages slots on can-
ister bracket. See A of Figure 9-17.

CAUTION

Carefully inspect end of convoluted tube for cuts, tears,

f1945x9x
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
Pull canister bracket from canopy weldment. fuel pressure.

4. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,

C INSTALLATION, or INSTRUMENT CONSOLE/CAN-

OPY, FLHR/C/S/I, INSTALLATION.

FUEL PRESSURE REGULATOR

REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2. See FUEL FILTER CANISTER, REMOVAL, step 2.
f1944x9x 3. Slide fuel pressure regulator assembly forward to free
arms from catches on canopy weldment. See Figure 9-
Pull canister from fuel pressure regulator. 18.

Figure 9-17. Remove Fuel Filter Canister (FLHR/C/S/I)

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5. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
OPY, FLHR/C/S/I, INSTALLATION.

FUEL PUMP

REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2. Depress external latch and remove electrical connector
at top of fuel pump.
3. Using a side cutters, cut hose clamp and pull convoluted
f1943x9x
tube from fuel pump outlet port. Exercise caution to
Figure 9-18. Remove Fuel Pressure Regulator avoid cutting or damaging tube (and cracking or break-
(FLHR/C/S/I) ing outlet port).
4. Remove T15 TORX screw and pull fuel level sender from
post on fuel pump bracket.
5. Release end of return spring from hook on fuel pump
bracket.

CAUTION

Be absolutely certain fuel pump is faulty before remov-

ing hinge from support arm. Hinge is damaged during
Housing removal and requires replacement of the fuel pump and
bracket assembly.

O-Ring 6. Insert flat tip screwdriver at location shown in Figure 9-

f1931x9x 20. Carefully crack plastic webbing at top of hinge and
remove from support arm. Discard fuel pump and
Figure 9-19. Fuel Pressure Regulator Assembly bracket assembly.
7. Inspect the condition of the fuel pump wiring. If the wir-
ing needs to be replaced, see FUEL PUMP/FUEL
4. Remove fuel pressure regulator from housing. To over- LEVEL SENDER WIRING on the next page.
come the resistance of two O-rings, insert blade of small
screwdriver into gap between regulator and housing and
gently pry regulator out. See Figure 9-19.
8399
5. Inspect O-rings for cuts, tears or general deterioration.
Screwdriver
Replace the O-rings if they have taken a definite set.

INSTALLATION
1. Apply a thin coat of clean engine oil to new O-rings.
Install O-rings in grooves of fuel pressure regulator. See
Figure 9-19.
2. Install fuel pressure regulator into housing.
3. Fit fuel pressure regulator assembly into canopy weld-
ment engaging arms in catches. See Figure 9-18.
4. See FUEL FILTER CANISTER, INSTALLATION, step 3. Figure 9-20. Crack Hinge to Remove From Support Arm

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INSTALLATION f1946x9x

1. Obtain new fuel pump and bracket assembly. Install new

hinge at top of fuel pump bracket, so that opening of
support arm slot is on the fuel level sender mount side.
2. Slide end of support arm into slot at top of hinge. Pull on
Push
hinge to verify that it is locked by pin on support arm.
Install free end of return spring onto hook on fuel pump
bracket. Pull

CAUTION

Carefully inspect end of convoluted tube for cuts, tears,

holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
3. Slide new hose clamp onto free end of convoluted tube
(to fuel filter canister inlet). Install tube onto outlet port of
fuel pump. Crimp clamp, but exercise caution to avoid
cracking or breaking outlet port. To disengage tabs from windows, simultaneously
4. Install electrical connector at top of fuel pump. Gently pull on one safety pin while pushing on the other.
tug on connector to verify that external latch is locked
and connector will not come free of terminals.
Pull terminals from wire block and cut.
5. Align two holes in fuel level sender with threaded hole
and post on fuel pump bracket. Install T15 TORX screw
in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).
6. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CAN-
OPY, FLHR/C/S/I, INSTALLATION.

FUEL PUMP/FUEL LEVEL SENDER

WIRING

CAUTION

Do not replace the special teflon coated fuel pump/fuel f1930x9x

level sender wiring with ordinary bulk wire. Ordinary
insulation materials may deteriorate when in contact Figure 9-21. Remove Wire Block and Cut Terminals
with gasoline.
NOTE
Damaged fuel pump and/or fuel level sender wiring requires 2. If present, cut cable strap to release wiring at bottom of
replacement of the fuel level sender unit. See FUEL LEVEL support arm.
SENDER on this page.
3. Unwind spiral tubing from fuel pump and fuel level
sender wiring.

FUEL LEVEL SENDER 4. Depress external latch and remove electrical connector
at top of fuel pump.

5. At bottom of canopy, remove socket terminal from spade

REMOVAL contact on connector clip.
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY, 6. Remove T15 TORX screw and pull fuel level sender from
FLHR/C/S/I, REMOVAL. post on fuel pump bracket.

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7. Remove socket terminals from 3-place Mini-Deutsch 5. Install electrical connector at top of fuel pump. Gently
connector on canopy. Proceed as follows: tug on connector to verify that external latch is locked
and connector will not come free of terminals.
NOTE
For additional clearance, pull wireform to release from slots 6. Wind spiral tubing around fuel pump (and fuel level
on fuel filter canister bracket, and then use hinge to swing sender) wiring.
wireform out of the way. Move canister bracket forward to dis- 7. Install new cable strap capturing wiring at bottom of sup-
engage tab from slot on canopy weldment. Remove socket port arm. Cut any excess cable strap material.
terminal from spade contact on connector clip.
8. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
a. At underside of canopy, take note of the rectangular INSTALLATION, or INSTRUMENT CONSOLE/CAN-
opening or window on each side of the connector OPY, FLHR/C/S/I, INSTALLATION.
body. Now take note of the tab inside each window.
b. Obtain two safety pins. On each side of connector
body, insert a safety pin between body and wire CANOPY CONNECTOR/O-RING
block until end of each pin appears in window. To
disengage tabs from windows, gently pull on one
safety pin while pushing on the other. See upper REMOVAL
frame of Figure 9-21. With tabs released, gently tug
on wires to release wire block from connector body. 1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
c. Pull the wire socket terminals out of the wire block.
FLHR/C/S/I, REMOVAL.
See lower frame of Figure 9-21. Cut off the socket
terminals and back the wires out of the wire block. 2. At bottom of canopy, remove socket terminal from spade
contact on connector clip.
d. Insert wire block back into connector body until tabs
lock in windows. One corner of wire block and con- 3. Remove wire block from connector body as described
nector body is square to prevent improper installa- under FUEL LEVEL SENDER, REMOVAL, steps 7(a)-
tion. 7(b), on this page.
4. Slide connector clip from slots on connector body.
INSTALLATION Remove connector body from canopy.
5. Remove O-ring from groove on connector body.
1. Insert socket terminals of new wiring into wire block.
Take note of the table below for wire locations.
INSTALLATION
Table 9-2. Fuel Level Sender/Fuel Pump
1. Apply a very thin film of clean H-D 20W50 engine oil to
Connector [141], 3-Place Mini-Deutsch O-ring. Install O-ring in groove of connector body.

Chamber Wire Color Function 2. Fit connector body into hole at top of canopy. At under-
side of canopy, install connector clip engaging slots in
1 Orange Pump Power connector body.
2 Yellow Sender Output 3. Insert wire block back into connector body until tabs lock
3 Black Ground in windows. One corner of wire block and connector
body is square to prevent improper installation.

NOTE 4. Install socket terminal onto spade contact on connector

clip.
A series of dots are molded into the wire end of the block to
indicate wire location, one dot indicating chamber 1, two dots 5. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
chamber 2, three dots chamber 3. (Wire location numbers INSTALLATION, or INSTRUMENT CONSOLE/CAN-
are also stamped below the terminals inside the Mini-Deutch OPY, FLHR/C/S/I, INSTALLATION.
pin housing.)

2. Gently tug on wires to verify that they will not back out of
wire block. FUEL SUPPLY CHECK VALVE/TUBE
3. Install socket terminal onto spade contact on connector
clip. NOTE
4. Align two holes in fuel level sender with threaded hole The in-tank check valve is housed in the quick-connect fitting.
and post on fuel pump bracket. Install T15 TORX screw The check valve prevents the fuel tank from draining when
in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm). the external supply line is disconnected.

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Convoluted
Tube SUPPLY CHECK VALVE/TUBE

O-Ring

Body Hex

Chrome Sleeve
f2048x9x

Figure 9-22. Supply Check Valve (Quick-Connect Fitting)

REMOVAL 3. Slide a 7/8 inch deepwell socket over chrome sleeve

engaging hex on quick-connect fitting. See Figure 9-22.
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
Looking down at top of fuel tank, rotate fitting in a clock-
REMOVAL, steps 1-13, or INSTRUMENT CONSOLE/
wise direction until it turns easily. Remove the fitting by
CANOPY, FLHR/C/S/I, REMOVAL, steps 1-12.
hand drawing convoluted tube out through hole at bot-
tom of fuel tank.
1WARNING
A small amount of gasoline may drain from the fuel sup-
ply line when disconnected from the fuel tank. Thor-
oughly wipe up any spilled fuel immediately. Dispose of INSTALLATION
rags in a suitable manner. Gasoline is extremely flamma-
ble and highly explosive. Inadequate safety precautions
could result in death or serious injury. CAUTION

Carefully inspect convoluted tube for cuts, tears, holes

1WARNING or other damage. Replace tube (with attached quick-con-
Exercise caution to avoid twisting the fuel supply line fit- nect fitting) if any damage is found. Even the smallest
ting, as any cracks in the plastic construction of the line hole can cause a reduction in fuel pressure.
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury. 1. Apply a very thin film of clean H-D 20W50 engine oil to
new O-ring. Slide O-ring down convoluted tube and into
2. Locate quick-connect fitting on left side of fuel tank. Pull
groove of new quick-connect fitting. See Figure 9-22.
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11. 2. Feeding convoluted tube through hole at bottom of fuel
tank, hand thread quick-connect fitting into bore. Look-
1WARNING ing down at top of fuel tank, rotate fitting in a counter-
clockwise direction until snug.
A small amount of gasoline may drain from the fuel tank
when the quick-connect fitting is removed. Thoroughly 3. Slide a 7/8 inch deepwell socket over chrome sleeve
wipe up any spilled fuel immediately. Dispose of rags in engaging hex on quick-connect fitting. Tighten fitting to
a suitable manner. Inadequate safety precautions could
22-26 ft-lbs (29.8-35.3 Nm).
result in death or serious injury.

9-24 2004 Touring: Fuel Injection

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1WARNING 1WARNING
Exercise caution to avoid twisting the fuel supply line fit- To avoid an uncontrolled discharge or spray of gasoline,
ting, as any cracks in the plastic construction of the line always be sure the quick-connect fitting is properly
can result in gas leaks. Gas leakage can cause fire or mated. A slight tug on the fuel supply line fitting will ver-
explosion which could result in death or serious injury. ify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
4. Pull up on chrome sleeve of quick-connect fitting and result in death or serious injury.
insert neck of fuel supply line fitting. While pushing up on
bottom of fitting, pull down on chrome sleeve until it 5. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
“clicks” into the locked position. INSTALLATION, steps 4-15, or INSTRUMENT CON-
SOLE/CANOPY, FLHR/C/S/I, INSTALLATION, steps 4-
14.

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NOTES

9-26 2004 Touring: Fuel Injection