Content .. 34 35 36 37 ..

Harley Davidson 2008 Touring Models. Service Manual - page 36

sm04030

Fuel pump fuse

Maxi-fuse

Figure 4-2. Fuse Blocks

sm04502

Quick connect fitting (chrome sleeve)

Fuel supply line fitting

Figure 4-3. Fuel Tank (Left Side View)

INSTALLATION

Install fuel tank onto frame backbone aligning front flange
holes with bosses on left and right side of frame. Be sure
that ignition coil connector conduit exiting front left side of
wire trough does not become pinched between fuel tank
flange and ignition coil bracket.

Start front fuel tank screws.

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

Pull up on chrome sleeve of quick-connect fitting and insert
neck of fuel supply line fitting. While pushing up on bottom
of fitting, pull down on chrome sleeve. A slight tug on the
fuel supply line fitting will verify that it is locked in position.

On FLHR/C models, move to bottom left side of fuel tank.
Mate pin and socket halves of fuel gauge connector [117],
4-place Multilock. Feed connector into tunnel at front of
fuel tank.

Install two screws to fasten rear fuel tank bracket to frame
backbone. Alternately tighten screws to 15-20 ft-lbs (20.3-
27.1 Nm). Install plastic trim cover over bracket.

Alternately tighten front fuel tank screws to 15-20 ft-
lbs (20.3-27.1 Nm). Install rubber caps over screws.
Properly installed, relief on inboard side of cap is at the
bottom and lip is inboard of frame boss flange.

Connect fuel vapor vent tube to vapor valve fitting on top
plate.

Install fuel level sender/fuel pump connector [141], 4-place
Delphi. For best clearance with cam ring, tilt connector at
35° angle before installation.

Install console. Proceed as follows:

FLHR/C: Exercising caution to avoid pinching wire
harness and vent tube, position console on fuel tank.

FLHX, FLHT/C/U, FLTR: Remove filler cap, if
installed. Exercising caution to avoid pinching wire
harness, fuel overflow hose and vent tube, position
console on fuel tank. Install filler cap.

Start socket screw to fasten front of console to fuel
tank weldment.

Start hex screw to fasten rear console bracket to clip
nut on rear fuel tank bracket.

Alternately tighten socket/hex screws to 36-60 in-
lbs (4.1-6.8 Nm).

NOTE

If console rear bracket requires replacement, install new
bracket alternately tightening two screws to 20-30 in-
lbs (2.7-3.4 Nm).

10. Install seat. See

2.26 SEAT

11. Install maxi-fuse.

12. Install left side cover.

13. Install left side saddlebag. See

2.27 SADDLEBAGS

FUEL SUPPLY CHECK VALVE/TUBE

Removal

NOTE

The in-tank check valve is housed in the quick-connect fitting.
The check valve prevents the fuel tank from draining when the
external supply line is disconnected.

Remove top plate. See

4.5 FUEL TANK TOP PLATE

4-6 2008 Touring Service: Fuel System

Gasoline can drain from the fuel line when disconnected
from fuel tank. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
suitable manner. (00260a)

Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect.

Slide a deepwell socket over chrome sleeve engaging hex
on quick-connect fitting. See

Figure 4-4

Looking down at top of fuel tank, rotate fitting in a clock-
wise direction until it turns easily. Remove the fitting by
hand drawing fuel supply tube out through hole at bottom
of fuel tank. See

Figure 4-5

Installation

NOTE

Carefully inspect fuel supply tube for cuts, tears, holes or other
damage. Replace tube (with attached quick-connect fitting) if
any damage is found. Even the smallest hole can cause a
reduction in fuel pressure.

Apply a very light film of clean engine oil to new o-ring.
Slide o-ring down fuel supply tube and into groove of new
quick-connect fitting.

Feeding fuel supply tube through hole at bottom of fuel
tank, hand thread quick-connect fitting into bore. Looking
down at top of fuel tank, rotate fitting in a counterclock-
wise direction until snug.

Slide a deepwell socket over chrome sleeve engaging hex
on quick-connect fitting. Tighten fitting to 22-26 ft-lbs
(29.8-35.3 Nm).

To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
injury. (00268a)

Install top plate. See

4.5 FUEL TANK TOP PLATE

sm04504

Figure 4-4. Engage Hex on Quick-Connect Fitting

2008 Touring Service: Fuel System 4-7

sm04398

Chrome sleeve

Body hex

O-ring

Figure 4-5. Fuel Supply Check Valve/Tube

4-8 2008 Touring Service: Fuel System

4.5

FUEL TANK TOP PLATE

REMOVAL

TOOL NAME

PART NUMBER

CAM RING REMOVER/INSTALLER

HD-48646

NOTE

The gasoline in the fuel supply line is under high pressure (58
psi). To avoid an uncontrolled discharge or spray of gasoline,
always purge the line before top plate removal.

Purge the fuel supply line as follows:

Remove left side saddlebag. See

2.27 SADDLE-

BAGS

Remove left side cover.

Remove 15 amp fuel pump fuse.

Start the engine and allow the motorcycle to run.

When the engine stalls, operate starter for 3 seconds
to remove remaining fuel from fuel supply line.

Remove maxi-fuse.

Reinstall 15 amp fuel pump fuse.

Remove filler cap and drain fuel tank. Use a common
pump or siphon and an approved gasoline storage con-
tainer of sufficient capacity.

Remove seat. See

2.26 SEAT

Remove console. Proceed as follows:

Remove socket screw to release front of console from
fuel tank weldment.

Remove hex screw to release rear console bracket
from clip nut on rear fuel tank bracket.

Lay a clean shop towel on forward part of rear fender.

Remove console and lay upside down on shop towel.

Obtain CAM RING REMOVER/INSTALLER (Part No. HD-
48646) See

Figure 4-6

Place tool over top plate aligning four notches at bottom
with four tabs on cam ring.

Install 1/2 inch drive ratchet and rotate in a counter-
clockwise direction until cam ring is free. Push down on
tool during rotation to maintain full engagement with cam
ring. If disengagement occurs, tool may skip across the
surface of the fuel tank, resulting in scratches or other
damage. Remove tool.

NOTE

Always hold onto both the Cam Ring Remover/Installer and
ratchet during handling or separation of parts may cause one
to be dropped, possibly resulting in hard contact with fuel tank.
See

Figure 4-7

Remove cam ring and raise top plate.

Remove connector at bottom of top plate. For best results,
insert small flat blade screwdriver between latch and top
plate. Depress either side of latch while gently tugging on
harness.

10. Locate ground wire spade terminal in slot of top plate.

Insert tip of small flat blade screwdriver through window
to depress tang, and then pull terminal from slot. See

Figure 4-8

11. Depress collars to remove tubes from fittings on fuel filter

shell. Move top plate to bench area.

12. If top plate replacement is necessary, remove fuel filter

shell. See

4.6 FUEL FILTER

. See

Figure 4-9

sm04067

Figure 4-6. Cam Ring Remover/Installer (HD-48646)

sm04098

Figure 4-7. Hold Both Tool and Ratchet During Handling

2008 Touring Service: Fuel System 4-9

sm04068

Figure 4-8. Remove Ground Wire Spade Terminal From

Top Plate

sm04187

With Fuel Filter Shell

Without Fuel Filter Shell

Figure 4-9. Top Plate Assembly

INSTALLATION

TOOL NAME

PART NUMBER

CAM RING REMOVER/INSTALLER

HD-48646

If installing a new top plate, first install fuel filter shell. See

4.6 FUEL FILTER

Inspect seal ring at bottom of top plate for cuts, tears or
signs of deterioration. If necessary, install new seal ring
with the nubs contacting the ring groove walls.

Move top plate to motorcycle.

Connect tubes to fittings on fuel filter shell. Note that the
fittings are of different sizes to prevent improper assembly.
The tube with the smaller diameter fitting runs from the
fuel pump to the fuel filter housing, while the tube with the
larger diameter fitting runs from the fuel pressure regulator
housing to the fuel supply valve.

Install connector at bottom of top plate.

Route ground wire (from top plate connector) along inboard
side of vapor valve and install spade terminal into slot in
top plate. Gently tug on wire to verify that terminal is
locked.

NOTE

If terminal does not lock, use a thin flat blade, like that on a
hobby knife, to bend tang outward slightly away from terminal
body.

Install fuel tank top plate engaging index tab on OD in slot
at front of fuel tank collar.

Install cam ring over fuel tank top plate with the TOP stamp
up. See

Figure 4-10

NOTE

Remove filler cap from top plate on fairing equipped models,
if installed.

Obtain CAM RING REMOVER/INSTALLER (Part No. HD-
48646).

10. Place tool over top plate aligning four notches at bottom

with four index tabs on cam ring. Pushing down on tool
with both hands, rotate in a clockwise direction until each
of four index tabs begin to engage slots in fuel tank collar.

11. Install 1/2 inch drive ratchet and continue rotation of tool

until cam ring is fully installed. Push down on tool during
rotation to maintain full engagement with cam ring. If dis-
engagement occurs, tool may skip across the surface of
the fuel tank, resulting in scratches or other damage.
Remove tool.

NOTE

Always hold onto both the Cam Ring Remover/Installer and
ratchet during handling or separation of parts may cause one
to be dropped, possibly resulting in hard contact with fuel tank.
See

Figure 4-7

4-10 2008 Touring Service: Fuel System

12. Install console. Proceed as follows:

FLHR/C: Exercising caution to avoid pinching wire
harness and vent tube, position console on fuel tank.

FLHX, FLHT/C/U, FLTR: Exercising caution to avoid
pinching wire harness, fuel overflow hose and vent
tube, position console on fuel tank. Install filler cap

Start socket screw to fasten front of console to fuel
tank weldment.

Start hex screw to fasten rear console bracket to clip
nut on rear fuel tank bracket.

Alternately tighten socket/hex screws to 36-60 in-
lbs (4.1-6.8 Nm).

13. Install seat. See

2.26 SEAT

14. Install maxi-fuse.

15. Install left side cover.

16. Install left side saddlebag. See

2.27 SADDLEBAGS

17. Fill fuel tank. Carefully inspect for leaks. Start engine and

repeat inspection.

sm04196

Figure 4-10. Cam Ring Stamp

2008 Touring Service: Fuel System 4-11

4.6

FUEL FILTER

REMOVAL

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

Remove top plate. See

4.5 FUEL TANK TOP PLATE

Locate ground wire spade terminal in slot of fuel filter shell.
Insert tip of small flat blade screwdriver through window
to depress tang, and then pull terminal from slot. See

Figure 4-11

Gently raise locking arm and pull U-clip from holes in fuel
filter shell.

Remove fuel filter shell from end cap.

Remove o-ring and filter from fuel filter shell. See

Figure 4-12

sm04033

Figure 4-11. Remove Ground Wire Spade Terminal From

Fuel Filter Shell

sm04035

Filter shell

U-clip

O-ring

Filter

Figure 4-12. Fuel Filter Assembly

INSTALLATION

Install new filter in fuel filter shell.

Seat o-ring on counterbore at top of filter.

Install fuel filter shell over end cap, so that slot in fuel filter
shell engages index pin on end cap.

Holding parts together, slide U-clip through holes on
locking arm side of fuel filter shell. Push U-clip until ends
exit holes on opposite side. Retract U-clip until contact is
made with step in locking arm.

Route ground wire (from top plate TORX screw) around
index pin side of end cap and install spade terminal into
slot in fuel filter shell. Gently tug on wire to verify that ter-
minal is locked.

NOTE

If terminal does not lock, use a thin flat blade, like that on a
hobby knife, to bend tang outward slightly away from terminal
body.

Install top plate. See

4.5 FUEL TANK TOP PLATE

4-12 2008 Touring Service: Fuel System

4.7

FUEL PRESSURE REGULATOR

REMOVAL

Remove top plate. See

4.5 FUEL TANK TOP PLATE

Locate ground wire spade terminal in slot of fuel filter shell.
Insert tip of small flat blade screwdriver through window
to depress tang, and then pull terminal from slot. See

Figure 4-13

Remove spring clip from fuel pressure regulator. For best
results, free one side first and then the other.

Remove fuel pressure regulator, regulator seat, large o-
ring, screen and small o-ring. See

Figure 4-14

sm04033

Figure 4-13. Remove Ground Wire Spade Terminal From

Fuel Filter Shell

sm04032

Spring clip

Fuel pressure regulator

Regulator seat

Large o-ring

Screen

Small o-ring

Figure 4-14. Fuel Pressure Regulator Assembly

INSTALLATION

Insert small o-ring at top of pressure port bore.

Install screen at top of pressure regulator bore, so that
sleeve on ID faces small o-ring. Install regulator seat to
evenly press screen into bore. Remove regulator seat.

Install large o-ring at top of screen.

Install regulator seat and fuel pressure regulator.

Install spring clip, so that indented sides engage top of
center rib on fuel pressure regulator, while rounded side
engages bottom of tabs on housing.

Route ground wire (from top plate TORX screw) around
index pin side of end cap and install spade terminal into
slot in fuel filter shell. Gently tug on wire to verify that ter-
minal is locked.

NOTE

If terminal does not lock, use a thin flat blade, like that on a
hobby knife, to bend tang outward away from terminal body.

Install top plate. See

4.5 FUEL TANK TOP PLATE

2008 Touring Service: Fuel System 4-13

4.8

FUEL LEVEL SENDER

REMOVAL

Remove top plate. See

4.5 FUEL TANK TOP PLATE

Disconnect 2-place connector to release fuel level sender
from wire harness.

NOTE

Looking into fuel tank at bracketry at top of tunnel, note that
finger on front bracket points forward, while finger on rear
bracket points rearward. See

Figure 4-15

Reaching into fuel tank, pull up on front finger and slide
fuel level sender bracket rearward until four ears on
bracket are free of catches at top of tunnel.

Remove fuel level sender from left side of fuel tank. See

Figure 4-16

sm04400

Fuel level sender bracket (front finger)

Fuel level sender connector

Top plate connector

Figure 4-15. Front Finger (Fuel Level Sender Bracket)

sm04194

Figure 4-16. Fuel Level Sender

INSTALLATION

With the finger on the fuel level sender bracket pointing
forward, install fuel level sender into left side of fuel tank.

Engage four ears on fuel level sender bracket with front
set of catches at top of tunnel. Push fuel level sender
bracket forward until ears are fully engaged.

Connect 2-place connector to attach fuel level sender to
wire harness.

Install top plate. See

4.5 FUEL TANK TOP PLATE

4-14 2008 Touring Service: Fuel System

4.9

TWIST GRIP SENSOR

REMOVAL

Remove left side saddlebag. See

2.27 SADDLEBAGS

Remove left side cover

Remove maxi-fuse.

NOTE

Do not remove the switch housing assembly without first placing
the 5/32 inch (4.0 mm) cardboard insert between the brake
lever and lever bracket. Removal without the insert may result
in damage to the rubber boot and plunger of the front stoplight
switch. Use the eyelet of an ordinary cable strap if the card-
board insert is not available.

Place the cardboard insert between the brake lever and
lever bracket.

Using a T25 TORX drive head, remove the upper and
lower switch housing screws.

Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the master cylinder
housing. Remove the lower clamp screw with flat washer.

Separate the upper and lower switch housings and remove
the throttle grip from the end of the handlebar.

NOTE

To remove the throttle grip, a slight tug may be necessary to
release index pins in grip from receptacle in seal cap of twist
grip sensor.

If present, pull two cable clips on right side handlebar
switch conduit from holes in handlebar.

FLHR/C: Remove headlamp and handlebar clamp shroud.
See

2.45 HEADLAMP NACELLE: FLHR/C

. Remove twist

grip sensor jumper harness connector [204], 6-place Molex
(black), from T-stud on fork stem nut lock plate (right side)
and disconnect. See

Figure 4-17

10. FLHX, FLHT/C/U: Remove outer fairing. See

2.35 UPPER

FAIRING AND WINDSHIELD: FLHX, FLHT/C/U

. Remove

twist grip sensor jumper harness connector [204], 6-place
Molex (black), from T-stud at top of right fairing support
brace (inboard side) and disconnect. See

Figure 4-18

11. FLTR: Remove outer fairing and bezel. See

2.39 UPPER

FAIRING AND WINDSHIELD: FLTR

and

2.40 INSTRU-

MENT BEZEL: FLTR

, respectively. Disconnect twist grip

sensor jumper harness connector [204], 6-place Molex
(black).

NOTE

The external latch on the pin housing of the twist grip sensor
connector will break if the twist grip sensor is pulled too hard.
A broken latch prevents positive engagement of the pin and
socket housings. Since the connector is not serviceable, any
damage requires replacement of the twist grip sensor jumper
harness.

sm04182

Figure 4-17.Twist Grip Sensor Jumper Harness Connector

(FLHR/C)

sm04184

Figure 4-18.Twist Grip Sensor Jumper Harness Connector

(FLHX, FLHT/C/U)

2008 Touring Service: Fuel System 4-15

12. Gently pull twist grip sensor out of handlebar only as far

as necessary to access green twist grip sensor connector.
For best results, proceed as follows:

Straighten conduit on Molex connector end of jumper
harness and feed through slot at front of handlebar
while pulling.

If harness sticks inside handlebar while pulling twist
grip sensor, pull Molex connector end to retract har-
ness slightly, and then try again; gently work harness
back and forth in this manner until twist grip sensor
connector is accessible.

NOTE

The external latch on the pin housing of the twist grip sensor
connector will break if pried. A broken latch prevents positive
engagement of the pin and socket housings. Since the con-
nector is not serviceable, any damage requires replacement
of the twist grip sensor jumper harness.

13. Gently insert a small flat blade screwdriver between pin

and socket housings as shown in

Figure 4-19

. Once

bottom edge of latch is engaged, pull pin housing from
socket housing. Do not pivot or rotate screwdriver after
insertion or damage to pin housing will occur.

14. Remove twist grip sensor. See

Figure 4-20

sm04157

Figure 4-19. Gently Insert Screwdriver to Disconnect Twist

Grip Sensor Connector

sm04166

Figure 4-20. Twist Grip Sensor

INSTALLATION

NOTE

Each twist grip sensor contains the terminals for installation of
a heated throttle grip available through P&A. While the seal
cap protects the terminals from dirt and moisture, it also serves
as a retention device for installation of the throttle grip.

Verify that seal cap is installed at end of twist grip sensor.
If seal cap is not present, proceed as follows:

See if seal cap is engaged on index pins inside throttle
grip. If found, use a stiff piece of mechanics wire to
lasso seal cap and pull free of index pins. Obtain new
seal cap if damaged or missing.

Check condition of o-ring on seal cap. As o-ring is not
sold separately, install new seal cap if o-ring
replacement is necessary.

Install seal cap engaging legs in slots at end of twist
grip sensor. For best results, install one leg first.
Depressing second leg slightly with a small flat blade
screwdriver, push down on seal cap until fully
installed. See

Figure 4-21

Connect green twist grip sensor connector.

Gently pull Molex connector end of jumper harness to
draw twist grip sensor into handlebar. Fit index tabs on
twist grip sensor into slots in handlebar. One index tab
and slot are smaller than the others to prevent improper
assembly. See

Figure 4-22

Slide the throttle grip over the end of the handlebar. Rotate
the grip to verify that internal splines are engaged with
those on the twist grip sensor.

NOTE

It is not necessary to hold the throttle grip onto the handlebar.
Index pins in grip engage receptacle in seal cap of twist grip
sensor to prevent grip from sliding off.

Position the lower switch housing beneath the throttle grip,
so that ribs at end of throttle grip engage slot in lower
switch housing.

Position the upper switch housing over the handlebar and
lower switch housing.

Start the upper and lower switch housing screws, but do
not tighten. Verify that the wire harness conduit runs in
depression at bottom of handlebar.

Position the brake lever/master cylinder assembly inboard
of the switch housing assembly engaging the tab on the
lower switch housing in the groove at the top of the brake
lever bracket.

Align the holes in the handlebar clamp with those in the
master cylinder housing and start the lower screw (with
flat washer). Position for rider comfort.

NOTE

Do not pull the switch housings so far inboard as to cause the
throttle grip to bind or drag on the handlebar. Rotate the throttle
grip to verify that it freely returns to the idle position.

4-16 2008 Touring Service: Fuel System

sm04169

Figure 4-21. Install Seal Cap If Removed

sm04172

Figure 4-22. Install Twist Grip Sensor

10. Beginning with the top screw, tighten the handlebar clamp

screws to 72-80 in-lbs (8-9 Nm) using a T27 TORX drive
head.

11. Using a T25 TORX drive head, tighten the lower and upper

switch housing screws to 35-45 in-lbs (4-5 Nm).

NOTE

Always tighten the lower switch housing screw first, so that
any gap between the upper and lower housings is at the front
of the switch assembly.

12. Remove the cardboard insert between the brake lever and

lever bracket.

13. FLHR/C: Connect twist grip sensor jumper harness con-

nector and install on T-stud on fork stem nut lock plate
(right side). Install handlebar clamp shroud and headlamp.
See

2.45 HEADLAMP NACELLE: FLHR/C

14. FLHX, FLHT/C/U: Draw twist grip sensor jumper harness

connector and conduit forward to front of upper fork
bracket, and then route under right radio support bracket
to area behind fairing support brace. Connect connector

and install on T-stud at top of fairing support brace (inboard
side). Install outer fairing. See

2.35 UPPER FAIRING AND

WINDSHIELD: FLHX, FLHT/C/U

15. FLTR: Connect twist grip sensor jumper harness con-

nector. Install outer fairing and bezel. See

2.39 UPPER

FAIRING AND WINDSHIELD: FLTR

and

2.40 INSTRU-

MENT BEZEL: FLTR

, respectively.

16. If present, install two cable clips on right side handlebar

switch conduit into holes in handlebar.

17. Install maxi-fuse.

18. Install left side cover.

19. Install left side saddlebag. See

2.27 SADDLEBAGS

NOTE

Whenever a new twist grip sensor (or ECM) is installed, place
the engine run/stop switch in the RUN position and turn the
ignition/light keyswitch to IGNITION and then back to OFF four
times (without starting engine). Allow at least three seconds
to elapse between ignition cycles. As the ECM uses the first
four ignition cycles to establish the optimum idle speed, there
may be initial performance problems if the procedure is not
performed, such as high idle or hesitation when the throttle is
opened.

20. Turn the Ignition/Light Key Switch to IGNITION and apply

brake lever to test operation of brake lamp.

TWIST GRIP SENSOR JUMPER HARNESS

Removal

Remove twist grip sensor.

Obtain length of strong flexible mechanics wire.

NOTE

Be sure that mechanics wire is of sufficient strength to pull
conduit and connector through handlebar without breaking.
Wire length must also be long enough, so that free end is not
lost in handlebar when pulled.

Securely attach mechanics wire to jumper harness inboard
of twist grip sensor connector pin housing. For best results,
install mechanics wire on conduit to keep it from bunching
up inside handlebar when pulled. See

Figure 4-23

Gently pull Molex connector end of jumper harness to
draw conduit, connector and mechanics wire out through
slot at front of handlebar. If harness sticks inside
handlebar, pull on twist grip sensor connector end to
retract harness slightly, and then try again; gently work
harness back and forth in this manner until free. Remove
mechanics wire from jumper harness.

Installation

Move to mechanics wire exiting slot at front of handlebar.
Securely attach mechanics wire to jumper harness inboard
of twist grip sensor connector pin housing. For best results,
install mechanics wire on conduit to keep it from bunching
up inside handlebar when pulled.

2008 Touring Service: Fuel System 4-17

Gently pull opposite end of mechanics wire to draw con-
nector and conduit back through handlebar. For best res-
ults, proceed as follows:

Guide leading edge of connector and conduit through
slot at front of handlebar. Keep harness straight and
feed through slot while pulling.

If harness sticks inside handlebar, pull Molex con-
nector end to retract it slightly, and then try again;
gently work harness back and forth in this manner
until twist grip sensor connector is accessible.

Remove mechanics wire from jumper harness.

Install twist grip sensor.

sm04176

Figure 4-23. Fix Mechanics Wire to Twist Grip Sensor

Jumper Harness

4-18 2008 Touring Service: Fuel System

4.10

THROTTLE CONTROL ACTUATOR (TCA)

GENERAL

NOTE

The TCA is not sold separately. Damage or failure requires
complete replacement of the induction module. Also note that
tampering or removing TCA cover voids warranty. See

Figure 4-24

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the TCA.

sm04034

Figure 4-24. TCA

2008 Touring Service: Fuel System 4-19

4.11

ENGINE TEMPERATURE SENSOR (ET)

GENERAL

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the engine temper-
ature sensor (ET sensor).

REMOVAL

Remove maxi-fuse. See

8.5 SYSTEM FUSES AND

RELAYS

Loosen horn bracket bolt to front cylinder head. Remove
horn bracket bolt (with flat washer) from rear cylinder head
and swing horn bracket forward.

Pull back boot at back of front cylinder and remove ET
sensor connector [90].

Slide a deepwell socket over the sensor body hex and
turn counter-clockwise to loosen. When sensor turns
easily, pull out the deepwell socket and remove sensor
by hand. See

Figure 4-25

sm04501

Figure 4-25. ET Sensor

INSTALLATION

Hand start new ET sensor into bore at back of front cyl-
inder.

Slide deepwell socket over sensor body hex and tighten
to 120-180 in-lbs (13.6-20.3 Nm).

Install ET sensor connector [90]. Pull boot over connector
to keep out dirt and debris.

Install maxi-fuse. See

8.5 SYSTEM FUSES AND RELAYS

4-20 2008 Touring Service: Fuel System

4.12

INDUCTION MODULE

REMOVAL

TOOL NAME

PART NUMBER

INTAKE MANIFOLD WRENCH

HD-47250

Remove fuel tank. See

4.4 FUEL TANK

Remove air cleaner and backplate. See

4.3 AIR CLEANER

ASSEMBLY

Pull purge tube from fitting at top of induction module
(California models only). See

Figure 4-26

Remove T-MAP sensor connector [80].

Remove front fuel injector connector [84] and rear fuel
injector connector [85].

Remove TCA connector [211]. Cut anchored cable strap
to release connector conduit from front right side of
induction module.

Remove right side socket screws from front and rear cyl-
inder head flange adapters. For best results, use the

INTAKE MANIFOLD WRENCH (Part No. HD-47250). See

Figure 4-27

Loosen left side socket screws from flange adapters. Slots
in flanges make removal of screws unnecessary. For best
access, proceed as follows:

Loosen horn bracket screw to front cylinder head.
Remove horn bracket screw (with flat washer) from
rear cylinder head and swing horn bracket forward.

Remove elbow terminals from horn spade contacts
and release harness conduit from J-clamp.

Pull back boot at back of front cylinder and remove
ET sensor connector [90].

Slide induction module out right side of motorcycle.

10. Remove seals from flange adapters. Discard seals.

Remove flange adapters from outlet ports of induction
module.

2008 Touring Service: Fuel System 4-21

Content .. 34 35 36 37 ..