Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams - page 27

 

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Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams - page 27

 

 

520
SUPPLEMENT
5A. Use an industrial heat gun and apply heat uni-
42
formly to the bearing inner race for approximately
30 seconds.
5B. If a heat gun is not available, apply penetrating
oil to the inner race and crankshaft and allow the oil
to penetrate for 30 minutes.
6. Make sure the bearing puller is square to the
crankshaft so the bearing inner race is not out of
alignment with the crankshaft shoulder.
7. Slowly tighten the center screw (E, Figure 41)
and withdraw the bearing inner race (F) from the
crankshaft shoulder.
8. Remove the bearing puller, splitter and bearing
inner race from the crankshaft.
9. Remove the trust washer from the crankshaft.
Discard the thrust washer, it cannot be re-used.
10. Clean the sprocket shaft with contact cleaner.
Check the sprocket shaft for cracks or other dam-
age. If it is damaged, refer service to a
Harley-Davidson dealership.
Installation
The sprocket shaft bearing cone installer
(HD-997225-55B) is required to install the sprocket
shaft bearing inner race.
4B. If a heat gun is not available, apply penetrating
1. Support the crankshaft in a support fixture
oil to the inner surface of the bearing race and to the
(HD-44358), or an equivalent, with the bearing side
crankshaft shoulder. Install the new inner race (D,
facing up (A, Figure 42).
Figure 42) onto the crankshaft.
2. Thread the pilot shaft (B, Figure 42) onto the
5. Apply graphite lubricant to the threads of the pi-
crankshaft until it contacts the crankshaft
lot shaft and flat washer
3. Slide the new thrust washer (C, Figure 42) over
6. Slide the sleeve (E, Figure 42) onto the crank-
the sprocket shaft.
shaft until it contacts the bearing inner race.
7. Slide the new bearing (F, Figure 42) and flat
WARNING
In Step 4, never use the heat gun in
washer (G) over the pilot shaft until it contacts the
conjunction with the penetrating oil.
top of the sleeve.
The heat from the gun may ignite the
8. Thread the handle (H, Figure 42) onto the pilot
oil resulting in a fire.
shaft (B).
9. Slowly tighten the handle clockwise until the
4A. Place the new bearing race on the workbench.
bearing inner race bottoms on the crankshaft shoul-
Use heat gun and uniformly heat the bearing race
der.
for approximately 60 seconds. Wear heavy duty
10. Unscrew and remove all parts of the special
gloves and install the new inner race (D, Figure 42)
tool.
onto the crankshaft
2002-2005 MODEL SERVICE INFORMATION
521
Table 6 ENGINE SERVICE SPECIFICATIONS
New
Service limit
Item
in. (mm)
in. (mm)
Cylinder bore
Standard
-
3.752
(95.301)
Oversize 0.005 in.
-
3.757
(95.428)
Oversize 0.010 in.
-
3.762
(95.555)
Piston-to-cylinder clearance
Early style piston
0.0006-0.0017 (0.015-0.043)
0.003
(0.076)
Late style piston
0.0014-0.0025 (0.036-0.064)
0.003
(0.076)
Piston pin fit in piston
(2004-on models)
0.0007-0.0012 (0.018-0.030)
0.002
(0.051)
Valve stem-to-guide clearance (2005 models)
Intake
0.001-0.003 (0.0254-0.0762)
0.0038
(0.0965)
Exhaust
0.001-0.003 (0.0254-0.0762)
0.0038
(0.0965)
Valve seat width (2005 models)
Intake and exhaust
0.040-0.062 (1.02-1.58)
-
Valve stem protrusion (2005 models)
Intake and exhaust
2.005-2.039 (50.93-51.79)
-
Valve spring free length (2005 models)
Intake and exhaust
2.325
(59.06)
-
Camshaft support plate
Camshaft chain tensioner
shoe
-
0.090 (2.29)*
Camshaft bushing fit
-
0.0008
(0.0203)
Camshaft bushing
inside diameter
-
0.8545
(21.704)
* 1/2 thickness of shoe.
Table 7 REAR CAMSHAFT SPROCKET SPACERS
Part No.
in.
mm
25722-00
0.287
7.29
25723-00
0.297
7.54
25721-00
0.307
7.80
25719-00
0.317
8.05
25717-00
0.327
8.31
14
Table 8 ENGINE TORQUE SPECIFICATIONS
Cylinder head bolts
Refer to text
522
SUPPLEMENT
CHAPTER FIVE
CLUTCH AND PRIMARY DRIVE
CLUTCH ASSEMBLY
(2005 MODELS)
43
The clutch assembly is identical to prior to years
with the exception of the seal on the clutch inspection
cover. The O-ring has been replaced with a large gas-
ket. Install the new gasket as follows:
1. Position the new gasket with the rubber molding
and the words Toward Engine facing the chaincase
cover.
2. Align the triangular shaped hole in the new gasket
with the top hole in the clutch inspection cover.
CAUTION
4. Install the clutch inspection cover (Figure 43) and
Do not push the screw through the tri-
new gasket onto the chaincase cover and thread the
angular shaped hole in the new gasket
top screw part way in.
as the sealing qualities of the gasket
will be damaged.
5. Make sure the clutch inspection cover is correctly
aligned with the chaincase cover and install the re-
3. Insert the screw, with the captive washer, though
maining four screws with captive washers.
the clutch inspection cover and carefully thread it it all
the way through the triangular shaped hole in the
6. Use a T27 Torx driver and tighten the screws in a
new gasket.
crisscross pattern to 84-108 in.-lb. (9.5-12.2 N•m).
Table 9 CLUTCH TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N•m
Clutch inspection cover screws
-
84-108
9.5-12.2
2002-2005 MODEL SERVICE INFORMATION
523
CHAPTER SIX
TRANSMISSION
TRANSMISSION CASE
3. Check the shift arm shaft for wear or damage.
(2003-ON MODELS)
Check the end splines for wear or damage.
4. Check the shift rod lever for wear or damage.
Shift Arm Assembly
Check the internal splines for wear or damage.
Inspection
The shift arm adjustment procedure is the same as
on prior models with the following exceptions. The
SHIFTER ADJUSTMENT
some of the shift shaft components are now an integral
(2003-ON MODELS)
unit as shown in Figure 44.
1. Check the shift pawl for wear. Replace the shift
arm assembly if necessary.
The shifter arm adjustment procedure is the same
2. Check the spring for wear or damage. If the
as on prior models with the exception shift shaft com-
spring will not hold the pawl against the shift arm,
ponents. Some of the shift shaft components are now
replace it.
an integral unit as shown in Figure 45.
44
SHIFT ARM ASSEMBLY
14
1. Shift arm and pawl
7. Snap ring
2. Sleeve
8. Clamp bolt
3. Spring
9. Shift rod lever
4. Spring
10. Washer
5. Oil seal
11. Centering pin
6. Washer
524
SUPPLEMENT
45
SHIFT ASSEMBLY
1. Shift rod (FXDWG models)
15. Sleeve
31. Shift fork No. 1
2. Shift lever (FXDWG models)
16. Shift lever
32. Set screw
3. Washer
17. Snap ring
33. Centering pin
4. Acorn nut
18. Bearing
34. Oil seal
5. Bolt
19. Bolt
35. Washer
6. Washer
20. Support-right side
36. Snap ring
7. Shift lever
21. Shift drum
37. Shift rod lever
8. Shift peg
22. Support-left side
38. Bolt
9. Wave washer
23. Dowel pin
39. Spring
10. Wave spring
24. Sleeve
40. Shift cam pawl
11. Shift rod (all models
25. Detent follower
41. Spring
except FXDWG)
26. Spring
42. Transmission case
12. Bolt
27. Bolt
43. Retainer
13. Shift lever (all models
28. Shift fork shaft
44. Washer
except FXDWG)
29. Shift fork No. 3
45. Bolt
14. O-ring
30. Shift fork No. 2
2002-2005 MODEL SERVICE INFORMATION
525
CHAPTER SEVEN
FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
AIR FILTER BACKPLATE
Electronic Control Module and Sensors
Removal/Installation
The electronic control module (ECM), mounted
(Fuel Injected Models)
under electrical panel cover on the right side, deter-
mines the optimum fuel injection and ignition tim-
Air filter backplate service is identical to
ing based on input from six sensors. The sensors
carbureted models.
Figure 46 and their locations and functions are as
follows:
ELECTRONIC FUEL INJECTION (EFI)
1. The throttle position sensor (TP), located on the
front of the induction module and attached directly
This section describes the components and oper-
to the throttle shaft, indicates throttle angle. The
ation of the sequential port electronic fuel injec-
ECM calculates the air volume entering the engine
tion
(EFI) system. The advantages of a map
based on the throttle angle.
controlled fuel and ignition system working to-
gether are tremendous. It allows for the elimina-
2. The crankshaft positions sensor (CKP), located
tion of an inefficient cold start enrichment devise
towards the front of the left crankcase, is an induc-
and allows for accurate control of the idle speed.
tive type sensor. The ECM determines the engine
Without a carburetor there is no need for periodic
speed by how fast the machined teeth on the fly-
adjustments and altitude compensation is auto-
wheel pass by the sensor.
matic. Improved torque characteristics are
3. The engine temperature sensor (ET) is located
achieved, while at the same time allowing for
on the front cylinder head. The ECM adjusts the in-
greater fuel economy and low exhaust emissions
jector opening time based on input from this sensor.
due to the matching of the air/fuel ratio and igni-
tion point, dependent upon load conditions. En-
4. The intake air temperature sensor (IAT) is lo-
gine performance modification is possible by
cated inside the induction module (rear cylinder’s
installing an electronic control module
(ECM)
intake runner). The ECM determines the air density
14
with different map characteristics.
and adjusts the injector opening time based on input
Complete service of the system requires a
from this sensor.
Harley-Davidson Digital Technician and a number
5. The manifold absolute pressure sensor (MAP) is
of other specialty tools. However, basic trouble-
located on top of the intake module. The MAP mon-
shooting diagnosis is no different on a fuel-injected
itors intake manifold pressure (vacuum) and sends
machine than on a carbureted one. If the check en-
this information to the ECM.
gine light comes on or there is a drivability problem,
6. Idle air control (IAC) valve is located on top of
make sure all electrical connections are clean and
the induction module. The ECM controls the engine
secure. A high or erratic idle speed may indicate a
idle speed by opening and closing the IAC passage
vacuum leak. Make sure there is an adequate supply
around the throttle plate.
of fresh gasoline. If basic tests fail to reveal that
cause of a problem, refer service to a Harley-
Make sure the ECM is securely mounted within
Davidson dealership. Incorrectly performed diag-
the electrical panel assembly to prevent damage
nostic procedures can result in damage to the fuel
from vibration. Do not tamper with the ECM; it is
injection system.
sealed to prevent moisture contamination.
526
SUPPLEMENT
46
ENGINE SENSORS
1. Screw
2. Clamp
3. MAP sensor
4. Seal
5. Engine temperature
sensor
6. Screw-self tapping
7. Plate
8. Oil pressure switch
9. Wiring harness
10. O-ring
11. CKP sensor
12. Bolt
Fuel Supply System
The fuel supply line pressure is
55-62
psi
(379-427 kPa). A check valve is located on the fuel
Fuel pump and filters
line where it attaches to the fuel tank.
The fuel pump and filter assembly is located inside
the fuel tank. This assembly is part of the removable
Fuel Injectors
canopy attached to the top of the fuel tank. The can-
The solenoid-actuated constant-stroke pintle-type
opy provides easy removal and installation of the at-
fuel injectors consist of a solenoid plunger, needle
tached components without having to work within the
valve and housing. The fuel injector’s opening is fixed
fuel tank cavity. An inlet screen on the fuel pump and
and fuel pressure is constant.
the secondary fuel filter canister are located down-
stream from the fuel pump to provide maximum filtra-
The ECM controls the time the injectors open and
tion before the fuel reaches the fuel injectors.
close.
Fuel lines
Induction Module
The fuel line is attached to the base of the fuel
The induction module (Figure 47) consists of the
tank with a quick-disconnect fittings.
two fuel injectors, fuel pressure regulator, throttle po-
2002-2005 MODEL SERVICE INFORMATION
527
47
INDUCTION MODULE
REAR
FRONT
1. Throttle position sensor (TP)
5. Fuel injector (front cylinder)
2. Purge tube fitting
6. Idle air control valve (IAC)
(California models only)
7. Throttle cable bracket
3. Intake air temperature sensor (IAT)
8. Fuel injector (rear cylinder)
4. Manifold absolute pressure sensor (MAP)
14
sition sensor, intake air temperature sensor, idle speed
Gasoline will spurt out unless the system is
lever, fuel supply line fitting and the idle speed control
depressurized.
actuator.
1. Remove the cover from the electrical panel.
2. Remove fuel pump fuse (lower left side corner).
3. Start the engine and allow it to idle until it runs out
DEPRESSURIZING THE FUEL SYSTEM
of gasoline.
(FUEL INJECTED MODELS)
4. After the engine has stopped, operate the starter for
three seconds to eliminate any residual gasoline in the
The fuel system is under pressure at all times, even
fuel lines.
when the engine is not operating. The system must be
5. After all service procedures have been com-
depressurized prior to loosening fittings or discon-
pleted, install the fuel pump fuse and the electrical
necting fuel lines within the fuel injection system.
panel cover.
528
SUPPLEMENT
48
INDUCTION MODULE
1. Screw
2. Fuel supply line
3. Washer
4. Gasket
5. Mounting bracket
6. Fuel rail
7. Mouring bracket
8. Fuel injector
9. Manifold air pressure
sensor (MAP)
10. Induction module
11. Screw
12. Flange
13. Gasket
14. Bolt
15. Pin
16. Cable bracket
17. Idle air control valve (IAC)
18. Gasket
19. O-ring seal
20. Screw
21. Intake air temperature
sensor (IAT)
22. Gasket
23. Throttle position sensor (TP)
24. Throttle housing
INDUCTION MODULE
2. Remove the air filter assembly and backing plate
(FUEL INJECTED MODELS)
as described in Chapter Seven.
3. On California models, disconnect the EVAP hose
Removal
from the port on the induction module. Plug the end of
the hose to keep out debris.
Refer to Figure 48.
4. Carefully disconnect the electrical connector
1. Remove the fuel tank as described in this
from each fuel injector by rocking the connector
Supplement.
back and forth.
2002-2005 MODEL SERVICE INFORMATION
529
49
53
5. Disconnect the following electrical connectors
50
from the induction module:
a. IAT (A, Figure 49).
b. Idle air control (IAC) valve (B, Figure 49).
c. MAP.
d. TP sensor (Figure 50).
e. Fuel injectors.
6. Disconnect the throttle cables from the induction
module as described in this Supplement
NOTE
The front and rear intake manifold
flanges are different. If the flanges are
not marked, label them with an F and R
51
so they will be reinstalled in the correct
locations.
7. Working on the right side of the motorcycle,
loosen and remove the lower two bolts (Figure 51) se-
curing the cylinder head mounting flanges to the cyl-
inder heads. Loosen, but do not remove, the upper two
bolts securing the cylinder head mounting flanges to
the cylinder heads.
14
8. Working on the left side of the motorcycle, loosen
and remove the lower two bolts (Figure 52) securing
the cylinder head mounting flanges to the cylinder
heads. Loosen, but do not remove, the upper two bolts
52
securing the cylinder head mounting flanges to the
cylinder heads.
9. Slide the induction module part way out of the cyl-
inder head ports past the upper bolts.
10. Depress the button (A, Figure 53) on the fuel
line fitting. Disconnect the fuel line and fitting (B,
Figure 53) from the induction module fitting (C)
and remove the induction module.
11. Remove the mounting flanges and discard the
seals.
530
SUPPLEMENT
12. Inspect the induction module and fuel hoses as
54
described in this section.
THROTTLE CABLES
Installation
1. Install the flanges onto the correct side of the in-
duction module with the slotted hole at the top. Refer
to the marks made during Removal. Install new seals
onto the induction module.
2. Partially install the induction module and fuel
line assembly. Slide the fuel line connector (B, Fig-
ure 53) onto the induction module fitting (C) until it
clicks. Gently pull on the fuel line to ensure the fit-
ting is locked in place. Slide the induction module
on the upper two bolts.
3. Connect both throttle cables to the induction mod-
ule as described in this chapter.
4. Align the mounting flanges and install the two
lower bolts by hand. Use the same tool set up used
to loosen the bolts. Do not tighten the bolts at this
time.
5. Working on the right side of the motorcycle,
tighten the lower two bolts until snug, do not tighten to
the final torque specification at this time. Use the same
tool set up used to loosen the bolts.
6. Working on the left side of the motorcycle,
tighten the upper two bolts to 97-142 in.-lb. (11-16
N•m).
7. Working on the right side of the motorcycle,
1.
Handlebar
tighten the lower two bolts to 97-142 in..-lb. (11-16
2.
Upper housing
N•m).
3.
Lower housing
8. Carefully attach the electrical connector to each
4.
Friction shoe
5.
Snap ring
fuel injector. Align the grooves in the female connec-
6.
Spring
tor with the tabs in the male space housing. Push the
7.
Adjusting screw
connector halves together until both latches click.
8.
Screw
9.
Ferrule
NOTE
10.
Clip
In Step 9, push the electrical connec-
11.
Throttle grip
tor halves together until the female
12.
Throttle control cable
13.
Boot
latches slot connector is fully en-
14.
Idle control cable
gaged with the tabs on the male space
housing.
9. Connect the following electrical connectors
10.
On California models, connect the EVAP hose to
from the induction module:
the port on top of the induction module.
a. Fuel injectors.
b. TP (Figure 50).
11.
Install the air filter assembly as described in this
Supplement.
c. MAP.
d. IAC valve (B, Figure 49).
12. Install the fuel tank as described in this
e. IAT (A, Figure 49).
Supplement.
2002-2005 MODEL SERVICE INFORMATION
531
55
58
56
trol cable (A, Figure 55) and the rear cable is the idle
control cable (B).
At the induction control module, the idle control ca-
ble is located at the top of the throttle wheel (A, Fig-
ure 56) and the throttle control cable (B) is located at
the bottom.
57
Removal
1. Remove the fuel tank as described in this
Supplement.
2. Remove the air filter and backing plate as de-
scribed in Chapter Seven.
3. Make a drawing or take a picture of the cable rout-
ing from the induction module through the frame to
14
the right side handlebar.
4. At the right side handlebar, loosen both control ca-
ble adjuster locknuts (A, Figure 57), then turn the ca-
Inspection
ble adjusters (B) clockwise as far as possible to
increase cable slack.
Check the induction module assembly for wear, de-
5. At the induction module, perform the following:
terioration or other damage. Replace the seals as a set
if necessary. The throttle housing is not serviceable
a. Use needlenose pliers to disconnect the throttle
and must be replace if damaged.
cable (A, Figure 58) and the idle cable (B) from
the throttle barrel (C).
b. Carefully pull the throttle and idle control ca-
THROTTLE AND IDLE CABLES
bles from the integral cable guides in the in-
(FUEL INJECTED MODELS)
duction module.
There are two different throttle cables (Figure 54).
6. Release the cables from the integral cable guides in
At the throttle grip, the front cable is the throttle con-
the induction module.
532
SUPPLEMENT
CAUTION
Failure to install the spacer in Step 7
59
will result in damage to the rubber boot
and plunger on the front brake switch.
7. Insert a 5/32 in. (4 mm) thick spacer between the
brake lever and lever bracket. Make sure the spacer
stays in place during the following steps.
8. Remove the screws securing the right side switch
assembly together (A, Figure 59).
9. Remove the front master cylinder (B, Figure 59)
as described in Chapter Twelve.
10. Remove the brass ferrules from the notches on
3. Push the smaller diameter gold throttle cable insert
the inboard side of the throttle grip (Figure 60). Re-
into the smaller hole in the rear of the tension adjust-
move the ferrules from the cable end fittings.
ing screw. Push it in until it snaps into place.
11. Remove the friction shoe from the end of the ten-
4. Position the friction shoe with the concave side
sion adjusting screw.
facing up and install it so the pin hole is over the point
of the adjuster screw.
12. Remove the throttle grip from the handlebar.
5. Install the throttle grip onto the handlebar. Push it
NOTE
on until it stops, and pull it back about 1/8 in. (3.2
Use a rocking motion while pulling on
mm). Rotate it until the ferrule notches are at the top.
the control cable housings in Step 13. If
6. Place the lower switch housing below the throttle
necessary, place a drop of engine oil on
grip. Install the brass ferrules onto the cables so the
the housings retaining rings to ease
end fittings seat in the ferrule recess. Seat ferrules in
removal.
their respective notches on the throttle control grip.
Make sure the cables are captured in the molded
13. Pull the crimped inserts at the end of the throttle
grooves in the grip.
and idle control cable housings from the switch lower
7. Assemble the upper and lower switch housings
housing.
and the throttle grip. Install the lower switch housing
14. Remove the cables from the frame.
screws (A, Figure 59) and tighten them finger-tight.
15. Clean the throttle grip assembly and dry it thor-
8. If it is not in place, insert the 5/32 in. (4 mm) thick
oughly. Check the throttle slots for cracks or other
spacer between the brake lever and lever bracket.
damage. Replace the throttle if necessary.
Make sure the spacer stays in place during the follow-
16. The friction adjust screw is secured to the lower
ing steps.
switch housing with a circlip. If necessary, remove the
9. Install the front master cylinder (B, Figure 59)
friction spring, circlip, spring and friction adjust
as described in Chapter Twelve.
screw. Check these parts for wear or damage. Replace
10. Securely tighten the switch housing screws.
damaged parts and reinstall. Make sure the circlip
11. Remove the cardboard insert from the front mas-
seats in the friction screw groove completely.
ter cylinder.
17. Clean the throttle area on the handlebar with sol-
12. Operate the throttle and make sure both cables
vent.
move in and out properly.
13. Correctly route the cables from the handlebar to
Installation
the induction module.
14. At the induction module, perform the following:
1. Apply a light coat of graphite to the housing inside
a. Install the idle cable (B, Figure 58) ball end
surfaces and to the handlebar.
over the top of the throttle barrel (C) and install
2. On the lower switch housing, push the larger diam-
the cable ball end into the upper hole in the
eter silver throttle cable insert into the larger hole in
throttle barrel. Make sure it is properly seated.
front of the tension adjust screw. Push it in until it
b. Install the throttle cable (A, Figure 58) ball end
snaps into place.
under the bottom of the throttle barrel (C) and
2002-2005 MODEL SERVICE INFORMATION
533
NOTE
60
On models so equipped, always disarm
the optional TSSM security system
prior to disconnecting the battery or the
siren will sound.
1. Disconnect the negative battery cable as described
in Chapter Eight.
2. Remove the seat as described in Chapter Thirteen.
NOTE
It is not necessary to remove the five
short rings since they secure the top
install the cable ball ends into the lower hole in
plate trim ring to the base of the con-
sole.
the throttle barrel. Make sure they are properly
seated.
3. Remove the three long screws securing the fuel
c. Install the cables into the integral cable guides
cap trim ring and console to the top plate.
in the induction module.
4. Pull the fuel cap trim ring straight up and remove it.
15. At the throttle grip, tighten the cables to keep the
5. Remove the screw securing the rear portion of the
ball ends from being disconnected from throttle bar-
console. Pull the console and trim/gasket straight up
rel.
and remove it from the fuel tank.
16. Operate the hand throttle a few times. Make sure
6. If necessary, remove the fuel filler cap and O-ring
the throttle barrel operates smoothly with no binding.
from the top plate.
Also make sure both cable ends are seated squarely in
7. To remove the fuel gauge, perform the following:
their cable bracket guides and in the throttle barrel.
a. Remove the front and rear bolts, washers and
17. Adjust the throttle and idle cables as described in
acorn nuts securing the fuel tank.
Chapter Three.
b. Raise the fuel tank. On the left side, disconnect
18. Install the backing plate and air filter as described
the fuel gauge electrical connector from the
in Chapter Three.
main harness.
c. Pull the fuel gauge straight and gasket up and
19. Install the fuel tank as described in this chapter.
out of the top plate.
WARNING
8. Install the fuel gauge as follows:
Do not ride the motorcycle until the
a. Install the fuel gauge and new gasket into the
throttle cables are properly adjusted.
top plate.
Improper cable routing and adjustment
b. Connect the fuel gauge electrical connector
can cause the throttle to stick open. This
onto the main harness.
could cause loss of control.
14
c. Lower the fuel gauge and install the bolts,
washers and acorn nuts. Tighten the bolts and
20. Start the engine and allow it to idle in neutral.
nuts to 15-20 ft.-lb. (20-27 N•m).
Then turn the handlebar from side to side. Do not op-
9. If removed, install the fuel filler cap and O-ring
erate the throttle. If the engine speed increases when
onto the top plate.
turning the handlebar assembly, the throttle cables are
10. Install the trim/gasket onto the console and make
routed incorrectly or are damaged. Recheck cable
sure it is correctly seated around the console perimeter.
routing and adjustment.
11. Install console and trim/gasket straight onto the
fuel tank. Make sure it is correctly seated, and install
FUEL TANK CONSOLE
the screw securing the rear portion. Tighten the screw
to 18-24 in.-lb. (2.0-2.7 N•m).
Removal/Installation
12. Position the slot in the fill cap trim cap over the
(FXD, FXDI, FXDX, FXDXI Models)
tab on the console and install the trim cap.
13. Install the three long screws securing the fuel cap
Refer to Figure 61.
trim ring and console to the top plate. Tighten the
534
SUPPLEMENT
61
FUEL TANK CONSOLE
(FXD, FXDI, FXDX, FXDXI)
1. Screw
2. Screw
3. Fuel fill cap trim ring
4. Console
5. Mounting ring
6. Trim gasket
7. Top plate trim ring
8. Filler cap
9. Gasket
10. Top plate
11. Fuel restrictor
12. Screw
13. Gasket
14. Wiring harness
15. Fuel gauge
(FXDX, FXDXI models)
16. Connector
17. Connector
18. Fuel gauge
(FXD, FXDI models)
19. Gasket
2002-2005 MODEL SERVICE INFORMATION
535
screws to 18-22 in.-lb. (2.03-2.5 N•m). If the remain-
3. Remove the rear screw securing the leather trim
ing five screws were removed, tighten them to 18-22
panel to the fuel tank.
in.-lb. (2.03-2.5 N•m).
4. Place a towel on top of the fuel tank to protect the
14. Install the seat as described in Chapter Thirteen.
finish.
5. Remove the two screws securing the middle por-
tion of the console. Pull the console and trim/gasket
Removal/Installation
straight up and remove it from the fuel tank.
(FXDL, FXDLI Models)
6. Raise the fuel tank. Disconnect the speedometer
Refer to Figure 62.
and indicator lamp connectors from the main harness.
7. Install by reversing these removal steps. Note the
NOTE
following:
On models so equipped, always disarm
a.
Install the trim/gasket onto the console and
the optional TSSM security system
make sure it is correctly seated around the con-
prior to disconnecting the battery or the
sole perimeter.
siren will sound.
b.
Install console and trim/gasket straight onto the
1. Disconnect the negative battery cable as described
fuel tank. Make sure it is correctly seated.
in Chapter Eight.
c.
Install the mounting screws and tighten
to
2. Remove the seat as described in Chapter Thirteen.
18-24 in.-lb. (2.0-2.7 N•m).
3. Place a towel on top of the fuel tank to protect the
finish.
FUEL TANK
4. Remove the three screws securing the middle and
(2004-ON CARBURETED MODELS)
rear portion of the console. Pull the console and
trim/gasket straight up and place it on top of the fuel
WARNING
tank.
Some fuel may spill from the fuel tank
5. Disconnect the 12-pin electrical connector from
hose when performing this procedure.
both the speedometer and the tachometer.
Because gasoline is extremely flam-
6. Install by reversing these removal steps. Note the
mable and explosive, perform this
following:
procedure away from all open flames,
a. Install the trim/gasket onto the console and
including appliance pilot lights, and
make sure it is correctly seated around the con-
sparks. Do not smoke or allow anyone
sole perimeter.
to smoke in the work area, as an ex-
plosion and fire may occur. Always
b. Install console and trim/gasket straight onto the
work in a well-ventilated area. Wipe
fuel tank. Make sure it is correctly seated.
up any spills immediately.
c. Install the mounting screws and tighten to
18-24 in.-lb. (2.0-2.7 N•m).
WARNING
14
Route the fuel tank vapor hoses so that
they cannot contact any hot engine or
Removal/Installation
exhaust component. These hoses con-
(FXDWG, FXDWGI Models)
tain flammable vapors. If a hose melts
from contacting a hot part, leaking va-
Refer to Figure 63.
pors may ignite, causing a fire.
NOTE
On models so equipped, always disarm
Removal/Installation
the optional TSSM security system
prior to disconnecting the battery or the
The fuel hose is secured to the fuel tank
with
siren will sound.
non-reusable clamps. If the same type of clamp is go-
1. Disconnect the negative battery cable as described
ing to be reinstalled, purchase new ones before servic-
in Chapter Eight.
ing the fuel tank.
2. Remove the seat as described in Chapter Thirteen.
Refer to Figure 64.
536
SUPPLEMENT
62
FUEL TANK CONSOLE
(FXDL, FXDLI)
1. Tachometer
9. Reset switch rubber boot
2. Socket
10. Console
3. Gasket
11. Wiring harness
4. Screw
12. Clamp
5. Speed nut
13. Connector (12-pin)
6. Speedometer
14. Warning light
7. Socket
15. Back clamp
8. Gasket
16. Screw
2002-2005 MODEL SERVICE INFORMATION
537
63
FUEL TANK CONSOLE
(FXDWG, FXDWGI)
14
1. Speedometer
10. Ignition switch
2. Gasket
11. Screw
3. Bezel
12. Back clamp
4. Indicator lamp bezel
13. Indicator lamp assembly
5. Screw
14. Connector
6. Console
15. Trim gasket
7. Leather trim panel
16. Reset switch
8. Speed nut
17. Reset switch rubber
9. Push nut
boot
538
SUPPLEMENT
64
FUEL TANK-CARBURETED MODELS (2004-ON)
1. Vent hose-
13. Filter
fuel tank-to-vapor valve
14. Gasket
2. Bolt
15. Fuel shutoff valve
3. Filler cap
16. Hose clamp
4. Gasket
17. Fuel hose
5. Washer
18. Insulator
6. Clip
19. Vacuum hose
7. Acorn nut
20. Crossover hose
8. Fuel tank
21. Vent hose-
9. Acorn nut
vapor valve-to-atmosphere
10. O-ring
22. Clip
11. Adaptor
23. Vapor valve
12. Nut
2002-2005 MODEL SERVICE INFORMATION
539
NOTE
65
A crossover tube connects the two fuel
tank compartments. Drain both sides of
the tank before removing the tank in the
following steps.
5.
Drain the fuel tank as follows:
NOTE
A vacuum-operated fuel valve is in-
stalled on all carbureted models. A
hand-operated vacuum pump is re-
quired to drain the fuel tank.
a. Connect the drain hose to the fuel valve and se-
66
cure it with a hose clamp. Insert the end of the
drain hose into a gas can.
b. Disconnect the vacuum hose (Figure 66) from
the fuel valve.
c. Connect a hand-operated vacuum pump (Fig-
ure 67) to the fuel valve vacuum hose fitting.
d. Turn the fuel valve to the RES position.
CAUTION
In the following step, do not apply more
vacuum than 25 in. (635 mm) Hg or the
fuel valve diaphragm will be damaged.
e. Gently operate the vacuum pump handle and
67
apply up to a maximum of 25 in. (635 mm) Hg
of vacuum. Once the vacuum is applied the
fuel will start to flow into the gas can.
f. When fuel stops flowing through the hose, turn
the fuel valve off and release the vacuum. Dis-
connect the vacuum pump and drain hose.
6.
Disconnect the vent hose from the fuel tank.
7.
Disconnect the crossover hose from one side of the
14
fuel tank. Plug the tank opening and apply a hemostat
to the crossover hose.
8. Remove the front and rear bolts, washers and acorn
NOTE
nuts securing the fuel tank to the frame.
On models so equipped, always disarm
9. If the fuel tank console is still in place, perform the
the optional TSSM security system
following:
prior to disconnecting the battery or the
a. Partially lift off and remove the fuel tank.
siren will sound.
b. On the left side, disconnect the fuel gauge elec-
trical connector.
1.
Disconnect the battery negative cable.
10. Lift off and remove the fuel tank.
2.
Remove the fuel tank console as described in this
section, if necessary.
NOTE
3. Turn the fuel valve (A, Figure 65) to the OFF position.
Store the fuel tank in a safe place away
4. Remove the hose clamp and disconnect the fuel
from open flames or where it could be
hose (B, Figure 65) from the valve.
damaged.

 

 

 

 

 

 

 

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