Harley Davidson 2004 Touring Models. Service Manual - page 43
HOME
FLYWHEEL/CONNECTING ROD
ASSEMBLY
Removal
1.
See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-29.
2.
See Section 3.10 BOTTOM END OVERHAUL, DISAS-
SEMBLY, steps 1-18.
3.
See Section
3.11 SUBASSEMBLY SERVICE AND
REPAIR, CRANKCASE, LEFT CRANKCASE HALF,
SPROCKET SHAFT BEARING, REMOVAL.
f1690x3x
Inspection
1.
Replace the flywheel/connecting rod assembly if any of
Figure 3-136. Check Connecting Rod Side Play
the following conditions are noted:
● The crankshaft/sprocket shaft bearing inner races
CAUTION
are brinelled, burnt, scored, blued or damaged.
Do not attempt to straighten connecting rods. Straight-
ening rods will damage both the upper bushing and
2. Orient the assembly as shown in Figure 3-135. Holding
lower bearing.
the shank of each rod just above the bearing bore, pull
up and down on the connecting rods. Any discernable
● Connecting rods are bent or twisted.
up and down movement indicates excessive lower
● Connecting rods do not fall under their own weight
bearing clearance. Replace the flywheel/connecting rod
or are in a bind.
assembly.
NOTE
3. Insert a feeler gauge between the thrust washer and the
Bluing on connecting rods is from induction hardening and is
outboard side of the connecting rod. See Figure 3-136.
considered a normal condition.
Replace the assembly if rod side play exceeds 0.020
inch (0.51 mm).
NOTE
If the flywheel, connecting rods or right side bearing inner
race need to be replaced, then replace the entire flywheel
assembly.
Installation
1.
See Section
3.11 SUBASSEMBLY SERVICE AND
REPAIR, CRANKCASE, LEFT CRANKCASE HALF,
SPROCKET SHAFT BEARING, INSTALLATION.
2.
See Section 3.10 BOTTOM END OVERHAUL, ASSEM-
BLY, steps 1-29.
3.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
steps 1-39.
f1689x3x
Figure 3-135. Check Connecting Rod Bearing Clearance
3-108
2004 Touring: Engine
HOME
SPECIFICATIONS
4.1
CVH CARBURETOR JET SIZES
TORQUE VALUES
Main Fuel
Slow Fuel
Model
Item
ft/in-lbs
Nm
Jet No.
Jet No.
Enrichener cable
49 state
190
45
20-35 in-lbs
2.3-4.0 Nm
mounting bracket hex nut
HDI
195
45
Cylinder head breather
120-144 in-lbs
13.6-16.3 Nm
bolts
California
185
45
Air cleaner cover bracket
20-40 in-lbs
2.3-4.5 Nm
screws
Air cleaner cover screw
36-60 in-lbs
4.1-6.8 Nm
FUEL TANK CAPACITY
Fuel valve hex jam nut
15-20 ft-lbs
20-27 Nm
Fuel tank adapter
22-26 ft-lbs
30-35 Nm
Capacity
English
Metric
Fuel tank rear mounting
15-20 ft-lbs
20-27 Nm
bolt
Total
5.0 Gallons
18.9 liters
Fuel tank front mounting
Reserve
0.9 Gallons
3.4 liters
15-20 ft-lbs
20-27 Nm
bolts
Battery hold-down clamp
15-20 ft-lbs
20-27 Nm
bolt
Console mounting bolt
50-90 in-lbs
5.7-10.2 Nm
acorn nut
2004 Touring: Fuel
4-1
HOME
FUEL SYSTEM TROUBLESHOOTING (CARBURETED)
4.2
\
CARBURETOR TROUBLESHOOTING
OVERFLOW
Check for:
Remedy:
1.
Restricted fuel tank vent system.
1.
Correct restricted hose. Replace vapor valve.
2.
Loose float bowl screws.
2.
Tighten screws.
3.
Damaged float bowl O-ring.
3.
Replace O-ring.
4.
Improper fuel level in float bowl.
4.
Adjust float tab for correct fuel level.
5.
Damaged or leaking float assembly.
5.
Replace float assembly.
6.
Particle contamination in fuel inlet fitting cavity.
6.
Clean and clear cavity and fuel supply tract.
7.
Worn or dirty inlet valve or seat.
7.
Clean or replace valve and clean seat.
POOR IDLING
Check for:
Remedy:
1.
Idle speed improperly adjusted.
1.
Adjust operating idle speed.
2.
Inlet system air leak (faster idling).
2.
Correct as required.
3.
Loose low speed jet.
3.
Tighten jet.
4.
Contaminated or plugged low speed system.
4.
Clean contaminants and clear passages.
5.
Enrichener valve not seated or leaking.
5.
Adjust, clean or replace.
6.
Leaking accelerator pump.
6.
Repair.
POOR FUEL ECONOMY
Check for:
Remedy:
1.
High speed riding style.
1.
Modify riding habits.
2.
Excessive use of enrichener system.
2.
Limit system use.
3.
Fuel level too high.
3.
Adjust float level.
4.
Restricted fuel tank vent system.
4.
Correct restricted hose. Replace vapor valve.
5.
Dirty air cleaner element.
5.
Clean or replace as required.
6.
Excessive accelerator pump output.
6.
Check and clean accelerator pump bypass orifice.
7.
Plugged or restricted bowl vent.
7.
Clean and clear passages.
8.
Vacuum piston assembly malfunction.
8.
See Vacuum Piston Troubleshooting.
9.
Loose jets.
9.
Tighten jets.
10. Worn or damaged needle or needle jet.
10. Replace needle or needle jet.
11. Plugged air jets or passages.
11. Clean and clear passages.
12. Enrichener valve not seated or leaking.
12. Adjust, clean or replace.
13. Idle speed improperly adjusted.
13. Adjust operating idle speed.
POOR ACCELERATION
Check for:
Remedy:
1. Throttle cables misadjusted.
1.
Adjust throttle cables.
2. Inlet system air leak.
2.
Correct as required.
3. Restricted fuel tank vent system.
3.
Correct restricted hose. Replace vapor valve.
4. Restricted fuel supply passages.
4.
Correct and clear restriction.
5. Plugged bowl vent or overflow.
5.
Clean and clear passages.
6. Enrichener valve not seated or leaking.
6.
Adjust, clean or replace.
7. Worn or damaged needle or needle jet.
7.
Replace assembly.
8. Vacuum piston malfunction.
8.
See Vacuum Piston Troubleshooting.
9. Plugged jets or passages.
9.
Clean and clear as required.
10. Fuel level (float chamber) too low.
10. Adjust float level.
11. Accelerator pump leaking or no output.
11. Repair as necessary.
4-2
2004 Touring: Fuel
HOME
HARD STARTING
Check for:
Remedy:
1. Enrichener system plugged, not properly functioning
1. Clean, adjust, or replace; or read Owner’s Manual.
or improperly operated.
2. Correct as required.
2. Inlet system air leak.
3. Check fuel supply and/or passages. Verify that vacuum
3. Restricted fuel supply.
operated fuel valve is functional.
4. Fuel overflow.
4. See Overflow Troubleshooting.
5. Plugged slow jet or passages.
5. Clean and clear jet or passages.
POOR PERFORMANCE ON ROAD
Check for:
Remedy:
1. Inlet system air leak.
1. Correct as required.
2. Restricted fuel tank vent system.
2. Correct restricted hose. Replace vapor valve.
3. Dirty or damaged air cleaner element.
3. Clean or replace.
4. Accelerator pump inoperative.
4. Repair as required.
5. Plugged bowl vent or overflow.
5. Clean and clear passages.
6. Vacuum piston assembly malfunction.
6. See Vacuum Piston Troubleshooting.
7. Loose or plugged fuel and air jets or passages.
7. Clean, clear and correct as required.
8. Worn or damaged needle or needle jet.
8. Replace assembly.
9. Restricted fuel supply tract.
9. Correct and clear restriction.
10. Enrichener valve not seated or leaking.
10. Adjust, clean or replace.
11. Idle speed improperly adjusted.
11. Adjust operating idle speed.
POOR HIGH SPEED PERFORMANCE
Check for:
Remedy:
1.
Inlet system air leak.
1.
Clean or replace.
2.
Restricted fuel tank vent system.
2.
Correct restricted hose. Replace vapor valve.
3.
Dirty or damaged air cleaner element.
3.
Clean or replace.
4.
Accelerator pump inoperative.
4.
Repair as required.
5.
Plugged bowl, vent or overflow.
5.
Clean and clear passages.
6.
Vacuum piston assembly malfunction.
6.
See Vacuum Piston Troubleshooting.
7.
Restricted fuel supply tract.
7.
Correct and clean restriction.
8.
Loose or plugged main jets or passages.
8.
Tighten, clean, clear as required.
9.
Improper fuel level.
9.
Adjust float level.
10. Worn or damaged needle or needle jet.
10. Replace assembly.
11. Enrichener valve not seated or leaking.
11. Adjust, clean or replace.
2004 Touring: Fuel
4-3
HOME
VACUUM PISTON ASSEMBLY TROUBLESHOOTING
PISTON DOES NOT RAISE PROPERLY
Check for:
Remedy:
1. Diaphragm cap loose, damaged or leaking.
1.
Tighten or replace cap.
2. Diaphragm pinched at lip groove.
2.
Reposition diaphragm lip.
3. Piston atmosphere vent blocked.
3.
Clear vent.
4. Piston vacuum passage plugged.
4.
Clean and clear passage.
5. Torn diaphragm.
5.
Replace piston diaphragm assembly.
6. Piston binding.
6.
Clean piston slides and body or replace piston.
7. Spring binding.
7.
Correct or replace spring.
8. Enrichener valve open, not seated or leaking.
8.
Adjust, clean or replace.
PISTON DOES NOT CLOSE PROPERLY
Check for:
Remedy:
1. Piston diaphragm ring dirty or damaged.
1.
Clean or replace piston.
2. Piston binding.
2.
Clean piston slides and body or replace piston.
3. Spring damaged.
3.
Replace spring.
4-4
2004 Touring: Fuel
HOME
ENRICHENER (CARBURETED)
4.3
GENERAL
f1381b2x
Idle Control
Cable
The carburetor is a constant velocity, gravity fed type with a
float operated inlet valve, a variable venturi, a throttle stop
screw for idle speed adjustment and a fuel enrichment sys-
Throttle Control
tem for starting. See Figure 4-1.
Cable
The fuel enrichment circuit will cause engine idle speed to
increase to approximately 2000 rpm with enrichener knob
Vacuum Fitting
pulled out fully and engine running at normal operating tem-
Vacuum Piston
(At Back)
perature. With enrichener knob pulled out partially and
Chamber
engine running at normal operating temperature, engine idle
speed will also increase above normal idle speed. The
increase in idle speed is intended to alert the rider that
engine is warmed up, and that enrichener knob should be
pushed in all the way. Continued use of enrichener after
engine is warmed up may cause fouled spark plugs.
Idle and transfer ports provide a balanced fuel mixture during
the transition period from stop to mid-range. A vacuum piston
controls venturi opening.
The carburetor is specifically designed to control exhaust
emissions. All jets are fixed. The idle mixture has been pre-
set at the factory.
The idle mixture screw is recessed in the carburetor casting.
The opening is sealed with a plug because it is intended that
Idle Speed
the idle mixture be non-adjustable.
Set Screw
NOTE
Air
Jets
Adjusting mixture setting by procedures other than specified
in this section may be in violation of Federal or State regula-
Accelerator
tions.
Pump Nozzle
Float Chamber
This system partially compensates for changes in the mixture
that are normally caused by changes in altitude. Because
Figure 4-1. CVH Carburetor
atmospheric pressure decreases as altitude increases, the
pressure difference in the upper and lower chambers is
reduced, which provides less fuel to the engine.
The carburetor is equipped with an accelerator pump. The
accelerator pump system uses sudden throttle openings
CAUTION
(rapid accelerations) to quickly inject fuel into carburetor ven-
turi to provide extra fuel for smooth acceleration.
Never accelerate the engine above 2500 RPM immedi-
ately after a cold start. Allow the engine to run slowly for
15-30 seconds. This will allow the engine to warm up and
OPERATION
let oil reach all surfaces needing lubrication. Extended
idling with enrichener in the full out position for a period
longer than 30 seconds is not recommended.
Enrichener
NOTE
The enrichener knob, located under the left side of the fuel
● H-D CV carburetors have an enrichener circuit that will
tank, controls opening and closing of the enrichener circuit in
cause the engine to idle at approximately 2000 rpm with
the carburetor. The enrichener knob can be adjusted to any
the engine at normal operating temperature and the
position, from full-in to full-out.
enrichener knob pulled fully out.
2004 Touring: Fuel
4-5
HOME
● The increase in idle speed is intended to alert the rider
that the engine is warmed up to normal operating tem-
perature and the enrichener knob should be pushed all
Full-In
(Normal Running Position)
the way in.
1/2-Way
● Continuing to use the enrichener when the engine is at
Position
full operating temperature WILL CAUSE FOULED
Full-Out
SPARK PLUGS.
(Cold Engine Starts)
CAUTION
Pay close attention to the vehicle's warm-up time. Either
excessive or insufficient use of the enrichener may
f1808x4x
cause poor performance, erratic idle, poor fuel economy
and spark plug fouling.
Figure 4-2. Set the Enrichener Knob
NOTE
The following starting and operating instructions for all carbu-
reted motorcycles should be viewed as recommendations
Warm Climate Or Hot Engine
only. They may be modified for individual vehicles.
Turn the fuel valve to the ON position. Turn the Ignition/Light
Key Switch knob to the IGNITION position. Turn the Engine
Stop Switch to the RUN position. Open throttle 1/8 - 1/4 turn.
Cool Engine
Press the Engine Start Switch to operate the electric starter.
DO NOT USE ENRICHENER.
Outside Temperature Cooler than 60˚ F
Turn the fuel valve to the ON position. BE SURE THAT THE
NOTE
THROTTLE IS CLOSED. Pull the enrichener knob to the “full
If the engine does not start after a few turns or if one cylinder
out” position. Turn the Ignition/Light Key Switch knob to the
fires weakly but engine does not start, it is usually because of
IGNITION position. Turn the Engine Stop Switch to the RUN
an over-rich (flooded) condition. This is especially true of a
position. Press the Engine Start Switch to operate the electric
hot engine. If the engine is flooded, push enrichener knob in
starter.
all the way, turn ignition on and operate starter with throttle
wide open. DO NOT "pump" the throttle while turning over the
1. After initial 15-30 second warm-up, ride for 3 minutes or
engine.
2 miles (3.2 km) with enrichener knob in full out position.
See Figure 4-2.
2. Push the enrichener knob in to the 1/2 way position. Ride
ADJUSTMENTS
an additional 2 minutes or 2 miles (3.2 km).
3. Push the enrichener knob fully in.
Slow Idle
NOTE
If outside temperature is cooler than 20˚ F it may be neces-
NOTE
sary to pump the throttle control grip 2 or 3 times.
Make certain the enrichener knob is pushed all the way in
before adjusting engine idle. The CV carburetor enrichener-
circuit will cause the engine idle speed to increase to
Outside Temperature Warmer than 60˚ F
between 1500 and 2000 rpm with the enrichener knob pulled
Turn the fuel valve to the ON position. BE SURE THAT THE
out fully and the engine at normal operating temperature.
(With the enrichener knob pulled out partially and normal
THROTTLE IS CLOSED. Pull the enrichener knob to the “full
out” position. Turn the Ignition/Light Key Switch knob to the
engine operating temperature, the engine idle speed will
increase above normal idle speed (950-1050 rpm) to approxi-
IGNITION position. Turn the Engine Stop Switch to the RUN
position. Press the Engine Start Switch to operate the electric
mately 2000 rpm maximum with the enrichener knob pulled
out fully). The increase in idle speed is intended to alert the
starter.
rider that the engine is warmed-up and the enrichener knob
1. After the initial 15-30 second warm-up, ride for 1 minute
should be pushed all the way in. Continued use of the
or 1/2 mile (0.8 km) with enrichener knob in full out posi-
enrichener, after engine is at normal operating temperature,
tion. See Figure 4-2.
may cause fouled spark plugs.
2. Push the enrichener knob in to the 1/2 way position. Ride
With the engine at normal operating temperature and the
an additional 1 minute or 1/2 mile (0.8 km).
enrichener all the way in (enrichener valve closed) adjust the
3. Push the enrichener knob fully in.
throttle stop screw so the engine idles at 1000 rpm.
4-6
2004 Touring: Fuel
HOME
NOTE
f1438x4x
Use a test tachometer, connected to negative ignition coil ter-
Mounting
Lockwasher
minal to measure engine rpm on models without tachome-
Bracket
Enrichener
ters.
Knob
Hex
Enrichener Control
Nut
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, inspect the
enrichener control as follows:
The fuel enrichener knob should open, remain open and then
close without binding. The knurled plastic nut next to the
enrichener knob controls the ease at which the cable slides
Knurled
Enrichener
Nut
Flat
within the conduit.
Cable
If adjustment is needed:
Figure 4-3. Enrichener Control
1.
See Figure 4-3. Loosen hex nut at backside of mounting
bracket.
2. Move cable assembly free of slot in mounting bracket.
5.
Slide enrichener cable into slot of mounting bracket. Flat
on threads must face rear of motorcycle for script on
3. Hold cable assembly at flat with adjustable wrench.
enrichener knob to be right side up. With external tooth
Hand turn knurled nut counterclockwise to reduce sliding
lockwasher and hex nut positioned on the inboard side
resistance until knob slides inward unaided.
of the mounting bracket, tighten hex nut to 20-35 in-lbs
4. Turn knurled nut clockwise to increase sliding resistance
(2.3-4.0 Nm).
until knob remains fully out without holding and then
closes with relative ease.
CAUTION
Do not lubricate the cable or inside of conduit. The cable
must have sliding resistance to work properly.
2004 Touring: Fuel
4-7
HOME
1.
Top
14.
Float
2.
Screw and washer (3)
15.
O-ring
3.
Spring
16.
O-ring
2
4.
Vacuum piston
17.
Screw and washer (4)
5.
Spring seat
1
18.
Cable guide
3
6.
Jet needle
19.
Starter cap
7.
Vacuum hose
20.
Cable sealing cap
8.
Needle jet
21.
Enrichener valve
9.
Needle jet holder
22.
Spring
10.
Main jet
23.
Bracket, throttle cable
11.
Slow jet
24.
Screw (throttle cable bracket)
12.
4-sided Fuel valve with clip
25.
Screw (throttle cable bracket)
13.
Pin
26.
Screw (idle speed adjust)
27.
Spring
28.
Collar
5
28
29.
Seal ring
30.
Manifold
31.
Flange
32.
Seal, intake manifold (2)
33.
Lever
34.
Float bowl
6
35.
E-clip
18
36.
Accelerator pump nozzle
31
30
47
4
19
20
31
7
29
32
22
21
24
26
23
a
vid
y
D
46
H
arle
27
25
48
49
52
11
50
33
35
53
12
37
49
51
8
45
13
15
54
44
9
14
16
37.
Spring
10
38.
Pump housing
39.
Spring
40.
Diaphragm
17
41.
O-Ring (2)
42.
Washer
43.
Screw (3)
44.
Boot
36
40
45.
Rod
46.
Collar
34
47.
Screw (4)
48.
Rod
39
49.
Cotter pin (2)
50.
Washer
NOTE
38
51.
Washer
With the exception of the jet sizes, all
41
52.
Washer
53.
Washer
FL models are equipped with the
42
54.
Collar
same basic carburetor.
f2277x4x
43
Figure 4-4. Carburetor
4-8
2004 Touring: Fuel
HOME
CARBURETOR
4.4
REMOVAL
Float Bowl
1WARNING
Vent
Gasoline is extremely flammable and highly explosive.
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Inadequate safety
precautions could result in death or serious injury.
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Remove air cleaner assembly. See Section 4.5 AIR
CLEANER, REMOVAL.
3.
Locate the fuel enrichener knob under the left side of the
fuel tank, and loosen hex nut at backside of mounting
8982
bracket. Slide cable assembly free of slot in mounting
bracket.
Figure 4-5. Drain Carburetor Float Bowl
4.
Rotate handle on fuel valve to the horizontal position to
shut the gasoline supply to the carburetor OFF.
1WARNING
8.
Using a needle nose pliers, carefully pull idle cable bar-
rel from upper inboard hole in throttle wheel. Pull throttle
Some gasoline will drain from the fuel inlet hose when
cable barrel from remaining hole. Release idle and throt-
disconnected from the carburetor. Thoroughly wipe up
tle cables from guides in throttle cable bracket.
any spilled fuel immediately. Dispose of rags in a suit-
able manner. Gasoline is extremely flammable and
9.
Pull vacuum hose elbow from fitting on inboard side of
highly explosive. Inadequate safety precautions could
carburetor.
result in death or serious injury.
10.
Carefully remove carburetor while drawing enrichener
5.
Using a side cutters, cut clamp and remove fuel inlet
cable to right side of motorcycle.
hose from fitting at side of carburetor.
11.
Keeping carburetor upright, move assembly to bench
NOTE
area. Tilting carburetor, carefully pour gasoline in float
On California models, pull purge tube from fitting on same
bowl into a suitable container. Gasoline will exit float
side of carburetor.
bowl vent shown in Figure 4-5.
6.
Gently work carburetor free of seal ring on intake mani-
fold.
INSTALLATION
1WARNING
As the carburetor is removed, be sure to keep assembly
1.
Place carburetor into approximate position on right side
upright as the float bowl contains gasoline. Tilting the
of motorcycle while feeding enrichener cable over to left
carburetor or turning it upside down will cause the gaso-
side.
line to drain onto surrounding area. Gasoline is
2.
Push vacuum hose elbow onto fitting on inboard side of
extremely flammable and highly explosive. Inadequate
carburetor.
safety precautions could result in death or serious
injury.
3.
Install sleeve on throttle cable housing into shorter cable
guide in throttle cable bracket. Drawing throttle cable
7.
If cruise control equipped, remove E-clip from groove at
downward, fit barrel end into lower outboard hole in
end of cruise cable housing. Remove cruise cable hous-
throttle wheel. Install sleeve and spring on idle cable
ing from cable guide in throttle cable bracket. Push plas-
housing into longer cable guide inserting barrel end into
tic end fitting on cruise cable to outboard side to release
upper inboard hole in throttle wheel.
from wheel pin.
2004 Touring: Fuel
4-9
HOME
10. Install air cleaner assembly. See Section
4.5 AIR
8981
CLEANER, INSTALLATION.
11. Install maxi-fuse. See Section
8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
12. Rotate handle of fuel valve clockwise to the vertical posi-
tion and carefully inspect for leaks. Return the valve to
the OFF position when finished.
13. Adust the engine idle speed. See Section
4.3
ENRICHENER (CARBURETED), ADJUSTMENTS.
DISASSEMBLY
Vacuum Piston Chamber
1. Placing a 14mm open end wrench on hex, loosen plastic
Figure 4-6. Remove Enrichener Cable
fitting at enrichener bore of carburetor housing. See Fig-
ure 4-6. Rotate enrichener cable in a counterclockwise
direction to unthread fitting and remove valve assembly.
4.
Verify that cables are fully seated in channel of throttle
2. Remove gold Phillips screw (with lockwasher) at side of
wheel, and using cable adjusters at handlebar, tighten
carburetor to release throttle cable bracket. Remove gold
cables as necessary to keep barrel ends from dislodging.
Phillips screw
(with top collar) to free throttle cable
Verify operation by turning throttle grip and observing
bracket from carburetor top. Set bracket aside.
cable action.
3. Remove three remaining top screws to release carbure-
5.
If cruise control equipped, slide plastic end fitting over
tor top from body.
cap of wheel pin. Push on end fitting until it snaps in
place. Slip cruise cable housing into cable guide in throt-
4.
Remove vacuum piston spring. Carefully raise dia-
tle cable bracket. Install new E-clip into groove at end of
phragm to remove vacuum piston assembly. Remove
cruise cable housing.
spring seat and jet needle from vacuum piston bore. See
Figure 4-7.
NOTE
The fit between the carburetor and seal ring is tight. Prior to
assembly, lubricate mating surfaces with liquid dishwashing
Float Chamber
soap or tire mounting lube. Always install new seal ring if
dried out, cracked or otherwise damaged.
1.
Turn carburetor upside down and remove four Phillips
6.
Lubricate inside diameter of seal ring. Also apply a light
screws at bottom to remove float bowl from carburetor
film of lubricant to carburetor housing where casting
body.
comes into contact with seal ring. Gently work carburetor
into seal ring.
7.
Slide new clamp onto free end of fuel inlet hose. Install
hose onto brass fitting at side of carburetor. Making sure
7754
clamp is positioned inboard of lip on fitting, crimp clamp
Vacuum
Piston
using HOSE CLAMP PLIERS (HD-97087-65B).
NOTE
Spring
On California models, push purge tube onto fitting on same
side of carburetor.
8.
Moving to left side of motorcycle, slide threaded portion
of enrichener cable into slot of mounting bracket. Flat on
threads must face rear of motorcycle for script on
enrichener knob to be right side up. With the external
tooth lockwasher and hex nut positioned on the inboard
side of the mounting bracket, tighten hex nut to 20-35 in-
Jet
Spring
lbs (2.3-4.0 Nm).
Needle
Seat
9.
Adjust throttle cables. See Section
2.21 THROTTLE
CABLES (NON-CRUISE), ADJUSTMENT.
Figure 4-7. Vacuum Piston Chamber Components
4-10
2004 Touring: Fuel
HOME
NOTE
Since accelerator pump rod is now loose, remove from hole
7751
A
Float
in lever at side of carburetor body.
CAUTION
Tapping the float pin out from the squared pedestal side
will result in damage that requires carburetor replace-
ment
Wireform
2.
Using a small center punch and hammer, carefully tap
Clip
float pin from holes in pedestals. The rounded pedestal
has an interference fit to ensure that the float pin is
securely held, so always tap out the pin in the direction
Float Pin
Fuel Valve
of the cast-in arrow (that is, from the interference side).
See Figure 4-8.
3.
Remove float and fuel valve. Carefully slide clip on fuel
7750
B
Needle Jet Holder
valve from tab on float. Remove wireform clip from
groove in fuel valve. See A of Figure 4-9.
4.
Using slot at top, turn main jet with flat tip screwdriver to
unthread from needle jet holder. If necessary, hold hex
on needle jet holder with a 5/16 inch wrench to prevent
rotation. See Figure 4-11.
Main Jet
5.
Using a 5/16 inch wrench, turn hex on needle jet holder
Needle Jet
to unthread from main jet bore.
6.
Turn carburetor right side up to drop out needle jet,
7755
which is loose in main jet bore. See B of Figure 4-9.
C
7.
Insert thin bladed flat tip screwdriver into slow jet bore.
See Figure 4-11. Using slot at top of slow jet, unthread
to remove. See C of Figure 4-9.
Slow Jet
8.
Disassemble accelerator pump from float bowl. See Fig-
ure 4-10. Proceed as follows:
Figure 4-9. Float Chamber Components
Rubber
f1868x4x
Boot
Rounded
Rod
Pedestal
Spring
Float Pin
Diaphragm
O-Rings
Figure 4-10. Accelerator Pump Components
Arrow
a. Remove rubber boot from post at top of accelerator
pump upper housing.
b. Turn float bowl upside down. Alternately loosen and
a0183x4x
then remove three Phillips screws
(with lock-
washers) to release accelerator pump lower hous-
Figure 4-8.
Remove Float Pin in Direction of Arrow
ing.
2004 Touring: Fuel
4-11
HOME
c. Remove spring and diaphragm from accelerator
Main Circuit
pump upper housing. Remove two O-rings from
a. Plugging main jet hole in carburetor throat, spray
lower housing.
carburetor cleaner into air inlet hole of main circuit.
See A of Figure 4-12. While spraying, verify that
solution exits main jet bore at bottom of carburetor
CLEANING AND INSPECTION
housing. See B of Figure 4-12.
b. Using a tapered, rubber-tipped nozzle on the air
Carburetor Housing
hose (to prevent both loss of air pressure and to
avoid scratching or nicking the bore), apply low pres-
1.
Clean all internal air/fuel passages in carburetor housing
sure compressed air into air inlet hole to blow carbu-
with carburetor cleaner. Blow out passages using low
retor cleaner out of hole in carburetor throat. Placing
pressure compressed air. Proceed as follows:
gloved finger over hole in carburetor throat, blow
carburetor cleaner out of main jet bore at bottom of
carburetor housing.
1WARNING
Compressed air can pierce the skin and cause injury.
Float Bowl Vent
Never use your hand to check for leaks or to determine
a. Spray carburetor cleaner into air inlet hole of float
air flow rates. Wear safety glasses to shield your eyes
bowl vent. See A of Figure 4-12. While spraying, ver-
from flying dirt and debris. Failure to comply could result
ify that solution exits two holes in float bowl chamber
in death or serious injury.
at bottom of carburetor housing. See B of Figure 4-
12.
Slow Speed Circuit
b. Using a tapered, rubber-tipped nozzle on the air
a.
Spray carburetor cleaner into air inlet hole of slow
hose (to prevent both loss of air pressure and to
speed circuit. See A of Figure 4-12. While spraying,
avoid scratching or nicking the bore), apply low pres-
verify that solution exits slow jet bore at bottom of
sure compressed air into air inlet hole of float bowl
vent to blow carburetor cleaner out of holes in float
carburetor housing. See B of Figure 4-12. Placing
gloved finger over slow jet bore, verify that solution
bowl chamber.
exits four pin holes just inboard of the throttle plate,
as well as the single pin hole outboard of the throttle
Vacuum Piston Chamber Components
plate.
1. Thorougly clean all loose parts (except diaphragm) with
b.
Using a tapered, rubber-tipped nozzle on the air
carburetor cleaner. See Figure 4-7. Blow dry using low
hose (to prevent both loss of air pressure and to
pressure compressed air.
avoid scratching or nicking the bore), apply low pres-
sure compressed air into air inlet hole to blow carbu-
retor cleaner out of slow jet bore. Placing gloved
1WARNING
finger over slow jet bore, blow carburetor cleaner out
Compressed air can pierce the skin and cause injury.
of pin holes inboard and outboard of throttle plate.
Never use your hand to check for leaks or to determine
air flow rates. Wear safety glasses to shield your eyes
from flying dirt and debris. Failure to comply could result
8979
in death or serious injury.
Slow Jet
2. Inspect parts as follows:
a. Hold vacuum piston up to strong light source. Exam-
ine diaphragm for pin holes, cuts, tears or pinching.
Replace if any damage is found.
b. Examine passage at bottom of vacuum piston bore.
Verify that passage is clean and open.
c. Examine vacuum piston spring for stretching, kink-
ing, distortion or other damage. Inspect spring seat
for cracks. Replace parts if necessary.
Main Jet
d. Examine slides at sides of vacuum piston to verify
that surfaces are clean and smooth. Clean or buff
Fuel Valve
out any rough surfaces.
Bore
e. Examine tip of jet needle for grooves or scratches.
Needle should be completely straight, while surface
condition at taper should be smooth and even.
Figure 4-11. Carburetor Housing
Replace needle if necessary.
4-12
2004 Touring: Fuel
HOME
b. Inspect float pin for damage or distortion. Replace
float pin if corroded, nicked or bent.
8980
c. Clean float and inspect for cracks or other damage.
A
Float Bowl
Submerge float in a glass of water. Replace float if
Vent
not water tight.
Air Inlet
d. Depress pin on fuel valve to verify that it returns to
the full-out position. Thoroughly clean valve with
carburetor cleaner if pin is dirty or sticks. Inspect
rubber cone on valve for dirt, cracks, hardening or
wear. Inspect wireform clip for distortion. Replace
fuel valve assembly if any of these conditions are
found.
e. Inspect fuel valve seat in carburetor housing for dirt,
damage or corrosion. Replace carburetor if seat
damage or corrosion is present.
Slow Speed
Main Circuit
Circuit
f.
Verify cleanliness of main jet, needle jet holder and
Air Inlet
Air Inlet
needle jet. Verify that orifices in needle jet holder
are clean and open. Replace parts if damaged.
g. Verify cleanliness of slow jet. Be sure that all orifices
Vent
8978
are clean and open. Replace jet if damaged.
Holes
B
Accelerator Pump
h. Inspect the accelerator pump diaphragm for holes,
cuts, tears or cracks. Replace diaphragm if
deformed or damaged.
i.
Examine spring for stretching, kinking or distortion.
Replace if any damage is found.
j.
Inspect the accelerator pump rod for straightness.
Replace the rod if bent.
Main Jet
k. Inspect rubber boot and two O-rings for cuts, tears
Bore
or signs of deterioration. Replace if necessary.
Slow Jet
Bore
ASSEMBLY
Figure 4-12. Clean Air/Fuel Passages
Vacuum Piston Chamber
Float Chamber Components
1.
Install vacuum piston into carburetor body. Slides on pis-
1.
Thorougly clean all loose parts with carburetor cleaner.
ton are offset, so piston will fit into slide track groove only
one way. If vacuum piston does not fit, rotate assembly
See Figure 4-9. Blow dry using low pressure com-
pressed air.
180°.
2.
Insert jet needle into vacuum piston bore, so that it
enters center hole at bottom. In the installed position,
1WARNING
head of needle contacts boss at bottom of vacuum pis-
ton bore, while length of shaft resides in main jet bore.
Compressed air can pierce the skin and cause injury.
Never use your hand to check for leaks or to determine
3.
With the legged side down, slide spring seat over top of
air flow rates. Wear safety glasses to shield your eyes
needle in vacuum piston bore. Slide spring over spring
from flying dirt and debris. Failure to comply could result
seat.
in death or serious injury.
4.
Verify that lip on edge of diaphragm is seated in groove
of carburetor flange.
2.
Inspect parts as follows:
NOTE
a. Inspect O-ring in groove of float bowl for cuts, tears
Diaphragm expands when in contact with fuel. If diaphragm
or signs of deterioration. Replace O-ring if distorted
is difficult to seat in groove because of this condition, allow
or if sealing surface is damaged.
diaphragm to dry before attempting to install.
2004 Touring: Fuel
4-13
HOME
5.
Fit free end of spring over boss on inboard side of carbu-
retor top, and keeping spring straight, align holes in top
A
Start Float Position
a0186x4x
with those in flange.
6.
Holding top to flange, check for proper diaphragm seal
by pushing up on vacuum piston (from intake side) and
releasing. If diaphragm is sealed correctly, very slight
resistance should be felt when pushing up, and piston
should be slow to extend. If piston movement is
restricted, spring is cocked. Lift up on top and then lower
carefully keeping spring coils straight.
Float
7.
Install three black top screws in holes furthest from throt-
tle wheel. Alternately tighten screws until snug.
Intake Manifold Side Down
8.
Slide gold top collar into remaining hole in carburetor top.
With end of idle screw resting against idle cam stop,
B
Correct Float Position
align holes in throttle cable bracket with those in carbure-
tor body and top cover. To prevent bending bracket or
cam stop, first install gold Phillips screw
(with lock-
washer) at side of carburetor. At carburetor top, install
remaining Phillips screw.
9.
Carefully insert enrichener valve into carburetor bore.
Float
Start threaded end of plastic fitting into bore, and then
rotate cable in a clockwise direction to install. Exercising
0.413- 0.453 in.
caution to avoid damaging the plastic construction,
(10.49-11.51 mm)
tighten fitting using a 14mm open end wrench. See Fig-
ure 4-6.
15˚ to 20˚
Pin Return Spring
Collapsed
Float Chamber
C Incorrect Float Position
1. Place needle jet into main jet bore. See Figure 4-11. Be
sure end with chamfered edge and larger ID goes in first.
2. Insert needle jet holder into main jet bore, and using a 5/
16 inch wrench, turn hex until snug.
Float
3. Thread main jet into needle jet holder. Using slot at top of
main jet, tighten with flat tip screwdriver until snug.
4. Insert slow jet into slow jet bore. See Figure 4-11. Insert
thin bladed flat tip screwdriver into bore, and using slot at
top of slow jet, tighten until snug.
Greater Than 20˚
5. Install wireform clip into groove on pin side of fuel valve,
if removed. Using wireform clip, carefully hang fuel valve
onto tab of float, so that tip of rubber cone hangs flush
Figure 4-13. Float Check and Adjustment
with top of float (the top being the side opposite the pivot
arm).
6. Place float into cavity of carburetor inserting fuel valve
7.
Insert float pin through squared pedestal and pivot arm
of float into rounded pedestal. Since the rounded pedes-
into bore between pedestals. See Figure 4-11.
tal has an interference fit to ensure that the float pin is
securely held, always install pin from the loose side (in
CAUTION
the direction opposite the cast-in arrow). Using a small
center punch and hammer, carefully tap float pin until
Tapping the float pin in from the rounded pedestal side
ends are flush with outboard sides of pedestals.
will result in damage that requires carburetor replace-
ment.
8.
Perform float level check as follows:
4-14
2004 Touring: Fuel
HOME
a. Place carburetor on a clean flat surface with the
f.
Install float and check float level again. Repeat pro-
intake manifold side down. See A of Figure 4-13.
cedure as necessary until float level is within specifi-
cation.
b. Tilt the carburetor 15° to 20° in a counter-clockwise
direction until float comes to rest. See B of Figure 4-
9.
Install new O-ring into groove of float bowl, if removed.
13.
Be sure to thoroughly clean groove before O-ring instal-
lation.
NOTE
The measurements will be incorrect if the carburetor is tilted
10.
Assemble accelerator pump as follows:
less than 15 ° or more than 20 °.
a. With the flat side toward the casting, install two O-
c. Using a dial vernier caliper or dial caliper depth
rings into counterbores of accelerator pump lower
gauge, measure the distance from the face of the
housing.
carburetor flange to the outboard edge of the float.
Be careful not to push on float while measuring.
b. Install diaphragm into accelerator pump upper
housing. Verify that lip on edge of diaphragm is fully
d. If the measurement is between
0.413 inch and
seated in groove.
0.453 inch (10.49 -11.51 mm), then the float level is
within specification. Proceed to step 9.
c. Place spring onto spring seat at center of installed
e. If the float level is not within specification, remove
diaphragm.
the float, and referencing the table below, carefully
d. Keeping spring straight, mate upper and lower
bend the tab slightly to adjust the float level. For
housings of accelerator pump. Install three Phillips
example, to increase the float measurement, bend
screws (with lockwashers).
the tab toward the carburetor body. This will have
the affect of decreasing the amount of gas in the
e. Install rubber boot onto post at top of accelerator
float bowl after assembly.
pump upper housing.
f.
Hook accelerator pump rod into hole on inboard
Table 4-1. Float Level Tab
side of lever at side of carburetor body.
Float
Amount of Gas
Bend Tab
11.
Install float bowl at bottom of carburetor body engaging
Measurement
in Float Bowl
free end of accelerator pump rod in hole of rubber boot.
Toward
To Increase
Decreased
12.
Install four Phillips screws to secure float bowl at bottom
Carburetor Body
of carburetor body. Tighten screws until snug.
Away From
To Decrease
Increased
Carburetor Body
2004 Touring: Fuel
4-15
HOME
AIR CLEANER
4.5
7.
Remove backplate from cylinder heads. On carbureted
GENERAL
California models, pull clean air inlet tube (to charcoal
canister) from hole on inboard side of backplate.
At the 1000 mile (1600 km) service interval, and at every
8.
Remove two O-rings from grooves around breather bolt
5000 mile (8000 km) service interval thereafter, inspect the
holes on inboard side of backplate. Discard O-rings.
air cleaner filter element, and clean or replace as necessary.
9.
Remove gasket from inboard side of backplate. Discard
gasket.
REMOVAL
CLEANING AND INSPECTION
1. Remove large allen head socket screw in center of air
cleaner cover. Remove air cleaner cover with rubber
seal. See Figure 4-14.
1.
Thoroughly clean air cleaner cover and backplate.
2. Remove three T27 TORX screws to release cover
2.
Replace the filter element if damaged or if filter media
bracket from filter element.
cannot be adequately cleaned.
3. Remove filter element pulling two breather tubes from
holes on inboard side.
1WARNING
4. Remove gasket from sleeve on inboard side of filter ele-
Do not use gasoline or solvents to clean the filter ele-
ment. Volatile or flammable cleaning agents may cause
ment. Discard gasket.
an intake system fire, which could result in death or seri-
5. Remove breather tubes from fittings on two cylinder
ous injury.
head breather bolts.
3.
Wash the filter element and breather tubes in warm,
6. Remove two cylinder head breather bolts from backplate
soapy water. To remove soot and carbon, soak element
using a 7/16 inch deepwell socket.
for 30 minutes in warm water with mild detergent.
f1650x4x
Cylinder Head
Breather
O-Ring
Breather Bolt
Tube
Cover
Bracket
T27 Torx
Air Cleaner
Screw
Cover
Gasket
Gasket
Filter
Backplate
Element
Cover Screw
Figure 4-14. Air Cleaner Assembly
4-16
2004 Touring: Fuel
HOME
NOTE
1WARNING
Air cleaner mounting without installation of the breather
Compressed air can pierce the skin and cause injury.
tubes allows crankcase vapors to be vented into the atmo-
Never use your hand to check for leaks or to determine
sphere in violation of legal emissions standards.
air flow rates. Wear safety glasses to shield your eyes
from flying dirt and debris. Failure to comply could result
in death or serious injury.
8.
Place filter element onto backplate with the flat side
down, so that hole on inboard side of element fits over
4.
Dry the filter element using low pressure compressed air
molded boss in backplate.
(32 psi/221 kPa maximum). Rotate the element while
9.
Align holes in cover bracket with those in filter element
moving air nozzle up and down the element interior. Do
and start three screws. Stamp on cover bracket points to
not rap the element on a hard surface.
downside. Using a T27 TORX drive head, alternately
5.
Hold the filter element up to a strong light source. The
tighten screws to 20-40 in-lbs (2.3-4.5 Nm).
element can be considered sufficiently clean if light is
uniformly visible through the media.
10.
Verify that rubber seal is properly seated around perime-
ter of air cleaner cover. Replace seal if cut, torn or shows
6.
Inspect the breather tubes for cuts, tears, holes or signs
signs of deterioration.
of deterioration. Replace as necessary. Direct com-
pressed air through breather tubes to verify that they are
11.
Fit air cleaner cover into backplate. Apply a small dab of
not plugged.
Loctite Medium Strength Threadlocker
243 (blue) to
threads of large allen head socket screw. Install screw in
center of air cleaner cover and tighten to 36-60 in-lbs
(4.1-6.8 Nm).
INSTALLATION
1. Install new O-rings in grooves around breather bolt
holes on inboard side of backplate.
2. Aligning flat edge of gasket with molded tab, install new
gasket on inboard side of backplate. On California mod-
els, install gasket by aligning small holes with plastic
pins.
3. On California models, push clean air inlet tube (to char-
coal canister) into hole on inboard side of backplate.
4. Align holes in backplate with those in cylinder heads and
install cylinder head breather bolts. Using a 7/16 inch
deepwell socket, alternately tighten bolts to
120-
144 in-lbs (13.6-16.3 Nm).
5. Slide new gasket over sleeve on inboard side of filter
element. Be sure holes in gasket are aligned with those
in filter.
6. Insert breather tubes about 1/4 inch (6.4 mm) into holes
on inboard side of filter element.
7. Install breather tubes onto fittings of two cylinder head
breather bolts.
2004 Touring: Fuel
4-17
HOME
VACUUM OPERATED FUEL VALVE (CARBURETED)
4.6
GENERAL
f1960x4x
A fuel valve is located under the fuel tank on the left side of
the motorcycle. The gasoline supply to the carburetor is
dependent upon the position of the valve handle as well as
Filter
the internal workings of the vacuum-operated valve.
Strainer
To access the main fuel supply, turn the valve handle down
to the fully vertical position, so that the indicator points up to
ON. To access the reserve supply, turn the handle up to the
fully vertical position, so that the indicator points down to
RES(ERVE). Move the handle to the horizontal position to
shut the gasoline supply to the carburetor OFF. Always turn
the valve to the OFF position to refuel, or whenever the
Carburetor
engine is not running.
Fuel Inlet
Hose
Gasoline will not flow through the fuel valve until the following
Jam
conditions are met:
Nut
1. The valve handle must be turned to the ON or
Vacuum
RES(ERVE) position.
Fitting
Gasket
2. A vacuum of approximately 0.5-1.0 inches of Mercury
(Hg) must be applied to the vacuum fitting at the back of
the fuel valve.
In service, the vacuum fitting is connected to the intake man-
ifold. The partial vacuum applied at the fitting creates a differ-
Hose
ence in pressure between the front side of the diaphragm
Clamp
(which is vented to the atmosphere via the bottom fitting on
Convoluted
the fuel valve) and the rear. This pressure differential causes
Tubing
the diaphragm to move against an internal spring, thereby
Fuel
opening an orifice that enables the flow of gasoline to the
Outlet
carburetor. When the vacuum at the vacuum fitting is
Fitting
removed, the internal spring pressure closes the orifice,
Valve
Atmospheric
which effectively halts the supply of fuel to the carburetor.
Handle
Pressure
Port
TROUBLESHOOTING
Figure 4-15. Vacuum Operated Fuel Valve
If the fuel valve is not functioning properly, refer to the trou-
1. Turn the handle of the fuel valve to OFF.
bleshooting chart on the next page.
1WARNING
REMOVAL
A small amount of gasoline may drain from the carbure-
tor fuel inlet hose when disconnected from the fuel valve
fitting. Thoroughly wipe up any spilled fuel immediately
DRAINING FUEL TANK
and dispose of rags in a suitable manner. Gasoline is
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious
1WARNING
injury.
Gasoline is extremely flammable and highly explosive.
When servicing the fuel system, do not smoke or allow
2.
Using a side cutters, cut clamp and remove hose from
open flame or sparks in the vicinity. Inadequate safety
fuel outlet fitting at the front of the fuel valve. See Figure
precautions could result in death or serious injury.
4-15. Drain free end of hose into a suitable container.
4-18
2004 Touring: Fuel
HOME
3. Remove elbow of intake manifold vacuum tube from fit-
CLEANING AND INSPECTION
ting on inboard side of the fuel valve.
4. Attach a length of fuel hose to the fuel outlet fitting. The
1.
Clean or replace the fuel filter strainer.
hose must be long enough to reach a suitable gasoline
2.
Flush the tank. See Section 4.7 FUEL TANK (CARBU-
container.
RETED), CLEANING AND INSPECTION.
5. Turn the handle of the fuel valve to RES(ERVE).
6. Using the correct hose adapter, connect the Mity-Vac®
INSTALLATION
Hand Pump (HD-23738A) to the vacuum fitting.
1.
Install a new gasket on the valve head.
CAUTION
2.
Install the fuel filter strainer fitting the internal tube into
To avoid damage to the diaphragm of the fuel valve, do
the larger hole in the valve head.
not apply a vacuum greater than 25 inches of Mercury
3.
Apply Loctite Pipe Sealant with Teflon 565 to threads of
(Hg) to the vacuum fitting.
fuel valve and fuel tank adapter.
4.
With the hex side down, turn the jam nut two full turns in
7.
Gently apply a vacuum of 1-10 inches of Mercury (Hg) to
the vacuum fitting to get a good flow of gasoline through
a counterclockwise direction to thread onto fuel tank
the valve.
adapter.
5.
Insert fuel filter strainer into fuel tank. Holding the hex
8.
When the fuel tank is completely drained, remove the
jam nut to prevent rotation, turn the fuel valve two full
Mity-Vac® Hand Pump from the vacuum fitting.
turns in a clockwise direction to thread onto hex jam nut.
9.
Holding fuel tank adapter, turn the hex jam nut in a
clockwise direction to remove the fuel valve assembly.
1WARNING
10.
Remove the fuel filter strainer from the valve head.
Do not thread fuel valve onto hex jam nut more than two
turns or nut may “bottom” on valve, a condition which
11.
Remove the hex jam nut from the fuel valve.
may result in a gasoline leak. Any gasoline leak is a
12.
Remove the gasket from the valve head. Discard the
potential fire hazard that could result in death or serious
gasket.
injury.
Table 4-2. Troubleshooting Vacuum Operated Fuel Valve
Problem
Cause
Solution
1. Vacuum valve not opening.
1.1
Hose not connected to
1.1.1
Connect hose to vacuum fitting.
vacuum fitting.
1.2
Leaking diaphragm.
1.2.1
Replace fuel valve assembly.
1.3
Hose connected to
1.3.1
Connect hose to vacuum fitting.
atmospheric pressure port.
1.4
Vacuum hose assembly
1.4.1
Replace vacuum hose assembly.
pinched or cracked.
2. Vacuum valve does not close.
2.1
Damaged sealing surface on
2.2.1
Replace fuel valve assembly.
valve side of diaphragm.
2.2
Plugged vacuum fitting.
2.2.2
Clean as necessary.
2.3
Broken or missing internal
2.3.1
Replace fuel valve assembly.
spring.
3.
Valve leaks gasoline at
3.1
Leaking diaphragm.
3.1.1
Replace fuel valve assembly.
atmospheric pressure port.
3.2
Loose diaphragm housing
3.2.1
Tighten screws.
screws.
2004 Touring: Fuel
4-19