Harley Davidson 2009 Dyna Models. Service manual - page 21

2009 Dyna Service: Fuel System 4-15

4.10

INDUCTION MODULE

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)

Gain access to the induction module by removing fuel tank
hardware and fuel line. Carefully pivot tank upward and
prop in position. See

4.6 FUEL TANK

Remove air cleaner backplate. See

4.5 AIR CLEANER

ASSEMBLY

See

. Pull purge hose from fitting (5) at top of

induction module (California models only).

See

Figure 4-18

. Pull idle cable barrel (1) from upper hole

in throttle wheel. Pull throttle cable barrel (2) from lower
hole. Using slots, release idle and throttle cables from
guides in throttle cable bracket.

. Remove idle air control connector (3)

[87] and manifold absolute pressure sensor connector (7)
[80].

Remove front fuel injector connector (1) [84] and rear fuel
injector connector (8) [85].

Remove throttle position sensor connector (4) [88] and
intake air temperature sensor connector (6) [89].

sm02356

MAP sensor [80]

Front fuel injector [84]

Throttle cable bracket

Rear fuel injector [85]

Rear mounting flange

IAC connector [87]

10.

TP sensor [88]

Fuel supply tube

11.

Front mounting flange

Purge hose fitting (used on California models only)

IAT sensor [89]

Figure 4-17. Induction Module

On left side of vehicle, loosen two hex screws holding front
and rear mounting flanges (9, 11) to cylinder head.

On right side of vehicle, remove two Allen screws holding
front and rear mounting flanges to cylinder head. Remove
induction module from vehicle.

Gasoline can drain from the fuel line when disconnected
from induction module. Gasoline is extremely flammable
and highly explosive, which could result in death or ser-
ious injury. Wipe up spilled fuel immediately and dispose
of rags in a suitable manner. (00269a)

4-16 2009 Dyna Service: Fuel System

10. See

Figure 4-20

. If fuel supply line (2) is being replaced,

squeeze ends of tab (1) and pull tab away from fuel supply
line to release from fuel supply tube (3).

11. Remove seals from flange adapters. Discard seals.

Remove flange adapters from outlet ports of induction
module.

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Idle cable barrel

Throttle cable barrel

Throttle wheel

Throttle cable bracket

Figure 4-18. Throttle/Idle Cables

INSTALLATION

See

. Place a new seal in each mounting

flange (9, 11) with the beveled side in against the counter-
bore.

NOTE

When induction module is positioned on manifold mounting
screws, be sure the flanges are installed correctly on the
manifold. Be sure the rubber seals are in place.

Place intake manifold seal, flanges, and induction module
in position. Install the manifold mounting screws finger
tight.

See

Figure 4-20

. Slide fuel supply line (2) onto fuel supply

tube (3). Push in on tab until it locks the fuel supply line
(2) on fuel supply tube (3). Tug on fuel supply line (2) to
verify it is locked into place.

Figure 4-18

. Install sleeve on throttle cable housing

into cable guide at top of throttle cable bracket (4). Drawing
throttle cable downward, fit barrel end (2) into lower hole
in throttle wheel (3). Install sleeve and spring on idle cable

housing into cable guide at bottom of throttle cable bracket
inserting barrel end (1) into upper hole in throttle wheel.

See

. On California models, attach purge hose

to fitting (5) on throttle body.

Connect front (1) and rear (8) fuel injector connectors, IAC
(3) connector, MAP sensor (7) connector, TP sensor (4)
connector and IAT (6) sensor connector.

Install air cleaner back plate. See

4.5 AIR CLEANER

ASSEMBLY

Tighten manifold mounting screws to 96-144 in-lbs (10.8-
16.3 Nm).

Turn the Ignition/Light Key Switch to ON and then back
to OFF to reset idle air control to park position.

10. Install air cleaner filter and cover.

11. Secure fuel tank. See

4.6 FUEL TANK

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Figure 4-19. EVAP Hose Connection

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Tab

Fuel supply line

Fuel supply tube

Figure 4-20. Fuel Supply Line

2009 Dyna Service: Fuel System 4-17

4.11

IDLE AIR CONTROL (IAC)

GENERAL

Refer to the ELECTRICAL DIAGNOSTIC MANUAL for
information on the function and testing of the idle air control
(IAC).

REMOVAL

Remove induction module. See

4.10 INDUCTION

MODULE

See

Figure 4-21

. Remove two fasteners (2) to release

throttle cable bracket (1) from induction module. Discard
fasteners.

Figure 4-22

. Pull IAC (1) and O-ring (2) from throttle

body.

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Throttle cable bracket

Fasteners

Idle air control (IAC)

Figure 4-21. Idle Air Control Location

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Idle air control (IAC)

O-ring

Figure 4-22. Idle Air Control

INSTALLATION

Figure 4-22

. Apply clean engine oil to IAC O-ring (2).

Install O-ring in counterbore of induction module.

With the electrical connector facing the rear left side of
the induction module, install idle air control into bore.

Place idle air control and o-ring into throttle body. Be sure
o-ring is properly seated in throttle body groove.

See

Figure 4-23

. Insert index pin (2) at bottom of throttle

cable bracket (1) into hole in boss at top of induction
module.

Figure 4-21

. Install new throttle cable bracket

fasteners (2). Tighten to 20-35 in-lbs (2.3-4.0 Nm).

Install induction module. See

4.10 INDUCTION MODULE

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Throttle cable bracket

Index pin

Figure 4-23. Throttle Cable Bracket

4-18 2009 Dyna Service: Fuel System

4.12

MANIFOLD ABSOLUTE PRESSURE SENSOR
(MAP)

GENERAL

Refer to the electrical diagnostic manual for information on the
function and testing of the temperature/manifold absolute
pressure (TMAP) sensor.

REMOVAL

Remove induction module. See

4.10 INDUCTION

MODULE

See

Figure 4-24

. Remove two fasteners (2) to release

throttle cable bracket (1) from induction module. Discard
fasteners.

Using appropriate tool, gently push up on MAP sensor
and attached seal to remove from intake manifold.

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Throttle cable bracket

Fasteners

Manifold Absolute Pressure Sensor (MAP)

Figure 4-24. Throttle Cable Bracket Location

INSTALLATION

NOTE

See

Figure 4-25

. If the original sensor is re-installed, the seal

(1) must be inspected. Seals not in good condition could cause
vacuum leaks. Install new seal if necessary.

Push MAP sensor and seal into intake manifold.

With the electrical connector facing toward the rear of the
induction module (side opposite throttle wheel), insert MAP
sensor into hole in induction module.

See

Figure 4-26

. Insert index pin (2) at bottom of throttle

cable bracket into hole in boss at top of induction module.

Figure 4-24

. Install new throttle cable bracket

fasteners (2). Tighten to 20-35 in-lbs (2.3-4.0 Nm).

Install induction module. See

4.10 INDUCTION MODULE

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Seal

MAP sensor

Figure 4-25. MAP Sensor

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Throttle cable bracket

Index pin

Figure 4-26. Throttle Cable Bracket

2009 Dyna Service: Fuel System 4-19

4.13

OXYGEN SENSOR

GENERAL

Refer to the electrical diagnostic manual for information on the
function and testing of the oxygen sensor (O2).

REMOVAL

Figure 4-27

. The (O2) sensors are installed in

threaded bosses on the inboard side of front and rear
exhaust pipes.

NOTE

See

Figure 4-28

. Front oxygen sensor connector is located in

front electrical caddy. For more information on the disassembly
and assembly of front electrical caddy see

7.6 VOLTAGE

REGULATOR

Open front electrical caddy and disconnect O2 sensor
connector (1). Remove any cable straps securing harness
before loosening and removing front O2 sensor.

Figure 4-29

. Remove seat. Disconnect sensor con-

nector and remove any cable straps securing harness
before loosening and removing rear O2 sensor.

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Figure 4-27. Oxygen Sensors (Inboard Side of Exhaust

Pipes)

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O2 sensor connector

CKP sensor connector

Figure 4-28. Front Electrical Caddy and Connectors

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Figure 4-29. Rear O2 Connector and Harness

INSTALLATION

NOTES

•

Do not install sensors that have been dropped or impacted
by other components. Damage to the sensing element
may have occurred. Replacement sensor assemblies have
threads coated with anti-seize lubricant and new seal
rings.

•

If reinstalling the O2 sensor, apply a thin coat of ANTI-
SEIZE LUBRICANT (Part No. 98960-97) to threads of
each oxygen sensor prior to installing in header. Do not
use any other grease or sealant product on sensor threads.
The electrical connector must also be clean and free of
any dielectric grease.

If sensor is being reinstalled, replace seal ring and coat
threads on sensor with LOCTITE ANTI-SEIZE.

Thread sensor into threaded boss on exhaust pipe and
tighten to 29-44 ft-lbs (39.3-59.7 Nm).

NOTE

Ensure both connector halves are clean and free of any
dielectric grease. Never use dielectric grease on sealed con-
nectors.

Route sensor harness to mating connector and connect.
Install cable straps that were removed during removal.

Repeat above for other sensor.

4-20 2009 Dyna Service: Fuel System

4.14

FUEL INJECTORS

GENERAL

Refer to the electrical diagnostic manual for information on the
function and testing of the fuel injectors.

REMOVAL

Remove induction module. See

4.10 INDUCTION

MODULE

NOTE

If not replacing fuel supply tube or o-rings, do not remove.

Figure 4-30

. Remove fastener (1) retaining fuel supply

tube (2).

Pull fuel supply tube from fuel rail. Remove sealing washer
(4) and o-ring (3) from fuel supply tube. Remove second
o-ring from fuel rail bore. Discard sealing washer and o-
rings.

Figure 4-31

. Pull fuel injectors with attached fuel rail

from induction module. To overcome the resistance of the
bottom O-ring on both fuel injectors, gently rock assembly
back and forth while pulling.

See

Figure 4-32

. Remove spring clips (2) from fuel

injectors. Pull fuel injectors from fuel rail. To overcome the
resistance of the top O-ring, gently rock each fuel injector
while pulling.

Remove o-rings (1) from fuel injectors. Discard O-rings.

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Fastener

Fuel supply tube

O-ring (2)

Sealing washer

Figure 4-30. Fuel Supply Tube

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Fork

Lip

Opening

Rail tab

Injector tab

Figure 4-31. Fuel Rail

INSTALLATION

Figure 4-32

. Apply a thin coat of clean engine oil to

new fuel injector o-rings (1). Install on fuel injectors.

Figure 4-31

. Push electrical connector side of fuel

injectors into fuel rail.

With the concave side toward the fuel rail, install spring
clip into slot on fuel injector. In the installed position,
openings (3) in sides of clip engage lip (2) on fuel rail,
while fork (1) at back of clip captures rail tab (4) on fuel
injector.

Rotate fuel injectors, so that the electrical connectors are
on the outboard side. Push fuel injectors into induction
module bores until tab on fuel rail engages machined slot
at top of induction module.

See

Figure 4-30

. Slide new o-ring (3) down shorter neck

of the fuel supply tube until it contacts the collar. Slide
new sealing washer (4) down tube until it contacts O-ring.
Install second o-ring (3) in fuel rail bore.

Push fuel supply tube (2) into fuel rail bore until clamp is
seated on round step of fuel rail. Install fastener (1) and
tighten to 90-110 in-lbs (10.2-12.4 Nm).

Install induction module.

4.10 INDUCTION MODULE

2009 Dyna Service: Fuel System 4-21

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O-rings

Spring clip

Figure 4-32. Fuel Injector

4-22 2009 Dyna Service: Fuel System

4.15

FUEL PUMP

GENERAL

When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)

Carefully inspect hose for cuts, tears, holes or other damage.
Replace hose if any damage is found. Even a small hole can
cause a reduction in fuel pressure.

Refer to the electrical diagnostic manual for information on the
function and testing of the fuel pump.

REMOVAL

To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

Purge the fuel supply line of high pressure gasoline.

See

Figure 4-33

. Remove the fuel pump fuse from

fuse block.

Start the engine and allow the vehicle to run.

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

sm02188

Figure 4-33. Fuel Pump Fuse

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect negative battery cable.

Remove instrument console.

For FXDC/FXDF models, see

7.21 INSTRUMENTS:

FXDC/FXDF

For FXDL, FXDB models, see

7.22 INSTRUMENTS:

FXDB/FXDL

For FXD models, see

7.19 FUEL GAUGE

Disconnect console wiring.

Gasoline can drain from the crossover line when discon-
nected from fuel tank. Gasoline is extremely flammable
and highly explosive, which could result in death or ser-
ious injury. Wipe up spilled fuel immediately and dispose
of rags in a suitable manner. (00259a)

Drain fuel tank.

Obtain a short section of hose (5/16 inch I.D.). Insert
bolt in one end of hose and install hose clamp to verify
that end is securely plugged.

See

Figure 4-34

. Cut clamp (1) from one end of

crossover hose (2). Quickly replace crossover hose
on fuel tank fitting with open end of short hose while
directing flow of gasoline from free end of crossover
hose into suitable container.

See

Figure 4-35

. Unplug fuel pump and sender connector

(1) [141].

Remove vent hose (3).

Remove top plate screws (2) and discard.

See

Figure 4-36

. On FXDL, FXDB, FXDF and FXDC

models, rotate top plate (3) until vent tube (1) clears fuel
tank.

sm02610

Clamp

Crossover hose

Figure 4-34. Fuel Crossover Hose

2009 Dyna Service: Fuel System 4-23

sm02192

Fuel pump and sender connector [141]

Screws (12)

Vent hose

Figure 4-35. Top Plate Screws (Typical)

sm02193

Vent tube

Gasket

Top plate

Figure 4-36. Fuel Line Clamp

10. See

Figure 4-37

. Depress tab and remove fuel

pump/sender wiring from top plate. Remove top plate.

11. See

Figure 4-38

. Depress tabs (1) and remove fuel line

(4) from fuel pump assembly (2).

12. Remove fuel gauge wiring harness (5) from clip (6).

13. Disconnect fuel pump connector (3).

14. See

Figure 4-39

. Lift fuel pump assembly tab. Push

assembly towards front of vehicle to disengage from fuel
tank.

15. Rotate fuel pump assembly clockwise and upward to

remove fuel pump assembly from fuel tank.

sm02194

Figure 4-37. Connector Tab

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Tabs (2)

Fuel pump assembly

Fuel pump connector

Fuel line

Fuel gauge wiring harness

Clip

Figure 4-38. Fuel Pump

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Figure 4-39. Fuel Pump Removal

4-24 2009 Dyna Service: Fuel System

sm02364a

10.

Regulator clip

Sender

11.

Top plate connector

Filter housing

12.

O-ring

Fuel pump/sender wiring

13.

Clip

Upper isolator

14.

Fuel pump

End cap

15.

Upper retainer

Lower isolator

16.

Lower retainer

Filter

17.

Regulator

Inlet sock

O-ring

Figure 4-40. Fuel Pump/Fuel Gauge Sending Unit

DISASSEMBLY/ASSEMBLY

Fuel Filter

Figure 4-41

. Depress tab and remove filter retainer

clip (1).

Separate fuel pump body from end cap (2).

Figure 4-42

. Remove O-ring (2).

Remove fuel filter (1).

Install new fuel filter.

Install new o-ring.

See

Figure 4-41

. Place end cap (2) on fuel pump body.

Install fuel filter retainer clip (1).

Regulator

See

Figure 4-43

. Remove wire terminal (3).

Disengage clip (2) from regulator.

Remove regulator from pump assembly.

Install new O-ring on new regulator.

Install regulator into pump assembly.

Install clip over regulator.

2009 Dyna Service: Fuel System 4-25

Replace wire terminal.

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Fuel filter retainer clip

End cap

Figure 4-41. Filter Retainer Clip

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Fuel pump filter

O-ring

Figure 4-42. Bail Bracket

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Regulator

Clip

Wire terminal

Figure 4-43. Regulator

Inlet Sock

Figure 4-44

. Depress tabs (2) securing inlet sock (1)

to upper retainer (3).

Remove inlet sock from upper retainer.

NOTE

See

Figure 4-45

. In next step, be sure inlet sock engages fuel

pump inlet.

See

Figure 4-44

. Install inlet sock (1) on upper retainer

(3). Be sure tabs (2) engage slots in body.

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Inlet sock

Tab (2)

Upper retainer

Figure 4-44. Fuel Sock

4-26 2009 Dyna Service: Fuel System

sm02618

Fuel pump inlet

Inlet sock

Figure 4-45. Fuel Sock Installation

Fuel Pump

See

Figure 4-46

. Using screwdriver, break tabs securing

fuel pump hose to end cap.

Remove inlet sock. See

4.15 FUEL PUMP

Figure 4-47

. Disconnect fuel pump connector (1).

Figure 4-48

. Depress tabs (1) and remove lower

retainer (2) from upper retainer.

Remove fuel pump from fuel pump body.

Figure 4-40

. Install lower isolator in lower retainer.

Install upper isolator into upper retainer.

Install fuel pump into upper retainer.

Figure 4-48

. Install lower retainer.

10. See

Figure 4-46

. Install fuel pump hose into new end cap.

11. See

Figure 4-47

. Install fuel pump connector (1). Inspect

fuel pump wiring, (2) replace if damaged.

12. Install inlet sock. See

4.15 FUEL PUMP

sm02619

Figure 4-46. Fuel Pump Hose Retaining Clip (2)

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Fuel pump connector

Wire harness

Wire clip

Figure 4-47. Fuel Pump Connector

sm02621

Tab (3)

Fuel pump lower retainer

Figure 4-48. Filter Retainer Clip

INSTALLATION

NOTE

Fuel pump sits in left side of fuel tank.

See

Figure 4-49

. Install fuel pump into left side of fuel tank

as shown.

Rotate pump counterclockwise and downward into posi-
tion.

See

Figure 4-50

. Install fuel pump so end cap (8) engages

mounting tabs (4).

Connect fuel pump connector (7).

Place fuel gauge wiring harness (5) into clip (6).

Install new O-ring on fuel line (1). Install fuel line.

Install new top plate gasket on fuel tank. Do not apply any
type of sealant to gasket.

2009 Dyna Service: Fuel System 4-27

sm02622

Figure 4-49. Fuel Pump Installation

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Fuel line

Tabs (2)

Fuel pump assembly

Mounting tabs (4)

Fuel gauge wiring harness

Clip

Fuel pump connector

End cap

Figure 4-50. Fuel Pump

Figure 4-51

. Install fuel pump/sender wire connector

(4) on top plate (3).

Install top plate.

On FXDL and FXDF models, hold top plate at 90°
angle.

Figure 4-52

. On all models, install sender wiring

into clip (3).

Figure 4-51

. On FXDL, FXDB, FXDC and FXDF

models, making sure that vent tube is installed inside
of tank, rotate top plate into position.

10. Loosely install new sealing screws in top plate.

11. On FXDC and FXDF models, see

Figure 4-54

. Tighten

sealing fasteners using pattern shown to 20 in-lbs (2.3
Nm).

12. On FXD/FXDB/FXDL models, see

Figure 4-55

. Tighten

sealing fasteners using pattern shown to 20 in-lbs (2.3
Nm).

13. See

Figure 4-53

. Connect fuel pump/sending unit con-

nector [141].

14. Install instrument console.

For FXDC/FXDF models, see

7.21 INSTRUMENTS:

FXDC/FXDF

For FXDL/FXDB models, see

7.22 INSTRUMENTS:

FXDB/FXDL

For FXD models, see

7.19 FUEL GAUGE

NOTE

In next step, be sure crimped end of clamp faces toward front
of vehicle.

15. Connect crossover hose with new clamps.

16. Connect the fuel pump fuse to the main wiring harness.

17. Connect negative battery cable.

18. Fill tank with gasoline and check for leaks.

19. Check fuel system pressure. See

4.16 FUEL PRESSURE

TEST

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Vent tube

Gasket

Top plate

Fuel pump/sender wire connector

Figure 4-51. Top Plate

4-28 2009 Dyna Service: Fuel System

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Fuel gauge sender

Removal tab

Connector

Figure 4-52. Fuel Gauge Sender

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Fuel pump and sender connector [141]

Screws (12)

Vent hose

Figure 4-53. Top Plate: FXDF

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Figure 4-54. Top Plate Torque Sequence (Typical)

2009 Dyna Service: Fuel System 4-29

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Figure 4-55. Top Plate Torque Sequence: FXD/FXDB/FXDL