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Harley Davidson 2005 touring models. Service repair manual - page 30

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8.

Slide electrical bracket onto studs at side of battery box.

Be sure that conduit is properly routed on inboard side of

A = Anchored

electrical bracket or wires may be pinched during instal-

lation. Install flange nuts and tighten to

36-48 in-lbs

Frame

(4.1-5.4 Nm).

Backbone

9.

Install ignition control module connector [10].

10. Mate pin and socket halves of main harness connector

1 A

[8]. Install connector into slot of electrical bracket. See

Figure 8-182.

11. Verify that protective plug is installed in data link connec-

tor [91]. With the plug side down and in contact with tab,

2 A

position connector between arms on electrical bracket.

12. Tighten cable straps securing ignition harness to right

side of frame backbone, upper frame tube and other wire

harness bundles. Cut any excess cable strap material.

3 A

13. Place battery in battery box, terminal side forward.

Rotate hold-down clamp so that lip (with rubber pad)

rests on edge of battery and tighten clamp bolt.

4 A

1WARNING

Saddlebag

Guard

Always connect the positive battery cable first. If the

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion producing personal injury and/or property

damage.

f2225x8x

14. Insert bolt through battery positive cable

(red) into

threaded hole of battery positive (+) terminal. Tighten

1

Captures ignition harness only. ANCHORED.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

2

3

4 Captures main harness, audio harness (FLHTCUI only),

ignition harness and conduit to fuel tank harness (all

15. Install fuel tank. See Section 4.7 FUEL TANK (CARBU-

models except FLHR/C/S). ANCHORED.

RETED), INSTALLATION

(AFTER COMPLETE

REMOVAL), FLHT/C or FLHR/S.

Figure 8-186. Remove/Install Cable Straps

16. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

17. Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

18. Start motorcycle and verify proper operation without set-

ting trouble codes.

8-150

2005 Touring: Electrical

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EFI HARNESS (FUEL INJECTED)

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REMOVAL

1. Remove fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), COMPLETE REMOVAL, FLHT/C/U/I,

FLTRI, or FLHR/C/S/I.

1

2. Remove air cleaner and backplate. See Section 4.5 AIR

CLEANER, REMOVAL.

3. Unthread bolt and remove battery positive cable (red)

from battery positive

(+) terminal.

(Battery negative

cable already removed under FUEL TANK, COMPLETE

REMOVAL.)

4. Using a T40 TORX drive head, loosen bolt to move lip of

hold-down clamp off edge of battery. Remove battery

from battery box.

2

5. Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

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

1. Vehicle Speed Sensor [65]

required).

2. P&A Security Siren [142]

NOTE

Figure 8-188. Electrical Bracket (Inboard Side)

Draw all EFI wire harness connectors to right side of motor-

cycle as they are disconnected.

8.

Remove idle air control connector [87] and manifold

7.

Carefully cut five cable straps to free EFI wire harness

absolute pressure sensor connector [80]. Pull external

from right side of frame backbone, upper frame tube and

latch(es) outward and use rocking motion to separate

other wire harness bundles. See Figure 8-191.

pin and socket halves. See Figure 8-187.

9.

Depress wire form to remove front fuel injector connec-

tor [84] and rear fuel injector connector [85].

[87A]

[84A]

Front

10.

Remove throttle position sensor connector

[88] and

intake air temperature sensor connector [89].

11.

Moving to left side of motorcycle, remove ignition coil

connector [83] from left side of ignition coil.

12.

Pull back boot to reveal engine temperature sensor con-

nector [90] at back of front cylinder. Pull external latch

outward and remove connector. Cut cable strap to

release conduit from horn bracket.

13.

Returning to right side of motorcycle, depress external

latch and remove ECM connector [78].

14.

Gently pull on data link connector [91] to disengage from

[85A]

[89A]

[88A]

arms on electrical bracket.

[80A]

15.

Locate painted white dot on inboard side of fuse block

[80A] Manifold Absolute Pressure Sensor

[119]. Pressing on dot, gently tug on conduit to release

[84A] Front Fuel Injector

tabs on fuse block from slots in bracket.

[85A] Rear Fuel Injector

16.

Pull main harness connector [8] from slot in electrical

[87A] Idle Air Control

bracket. Depress external latches and use a rocking

[88A] Throttle Position Sensor

motion to separate pin and socket halves.

[89A] Intake Air Temperature Sensor

f2162x9x

17.

Remove two flange nuts to release electrical bracket

from studs on side of battery box.

Figure 8-187. Induction Module Assembly (Top View)

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INSTALLATION

8321

1.

Standing on right side of vehicle, carefully feed sensor

connectors and conduit through opening into battery

box. See lower frame of Figure 8-189. Pull up on har-

ness and tuck conduit into space in front of the battery

box TORX screw.

CAUTION

Rubber

Damage to wires can result in electrical problems. Be

Boot

sure that rubber boot is present on threaded end of bat-

tery box TORX screw. Replace rubber boot if absent or

damaged. See upper frame of Figure 8-189.

2.

Draw sensor connectors and conduit up along right side

of frame backbone just below the main wire harness

bundle.

3.

Loosely install five new cable straps to secure EFI wire

harness to right side of frame backbone, upper frame

tube and other wire harness bundles. See Figure 8-191.

4.

Install front fuel injector connector

[84] and rear fuel

injector connector [85]. See Figure 8-187.

5.

Install manifold absolute pressure sensor connector [80]

and idle air control connector [87].

6.

Install intake air temperature sensor connector [89] and

throttle position sensor connector [88].

7.

Feed ignition coil and engine temperature sensor con-

nectors to left side of vehicle, routing the first in front of

the top engine stabilizer link, the latter to the rear.

8319

8.

Install ignition coil connector [83] onto left side of ignition

coil.

Figure 8-189. Remove EFI Harness From Vehicle

9.

Install engine temperature sensor connector [90] at back

of front cylinder. Pull boot over sensor to keep out dirt

and debris. Install new cable strap to secure connector

18. On inboard side of electrical bracket, disconnect vehicle

conduit to horn bracket.

speed sensor connector [65]. Depress button on socket

10.

Mate pin and socket halves of vehicle speed sensor con-

housing and pull apart pin and socket halves. See Fig-

nector [65].

ure 8-188.

11.

Install security siren connector [142] and vehicle speed

sensor connector

[65] on inboard side of electrical

CAUTION

bracket as shown in Figure 8-188. Be sure that conduit

and cables are properly routed or wires may be pinched

Damage to wires can result in electrical problems. Be

during installation.

sure that rubber boot is present on threaded end of bat-

12.

Slide electrical bracket onto studs at side of battery box.

tery box TORX screw. Replace rubber boot if absent or

Install flange nuts and tighten to 36-48 in-lbs (4.1-5.4

damaged. See upper frame of Figure 8-189.

Nm).

19. Note that harness conduit runs forward of the front bat-

13.

Mate pin and socket halves of main harness connector

tery box TORX screw. Pull conduit to the rear of the

[8]. Install connector into slot of electrical bracket.

screw, and then draw sensor connectors and conduit

14.

Engage tabs on fuse block [119] with slots in electrical

down right side of frame backbone into battery box.

bracket. Slide fuse block up into cavity. Gently tug on

20. Pull connectors and conduit out through opening at side

conduit to verify that fuse block is locked in place.

of battery box to remove harness from vehicle. See

15.

Install ECM connector

[78]. Push connector halves

lower frame of Figure 8-189.

together until latch clicks.

8-152

2005 Touring: Electrical

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[78B]

[65B]

[8A]

ECM Power

[91A]

Fuse

Fuel Pump

Fuse

Spare

[119B]

Fuse

EFI System

Relay

[88B]

[90B]

[89B]

[80B]

Rubber

Boot

[85B]

[84B]

[87B]

[8A]

Main Harness

[65B]

Vehicle Speed Sensor

[78B] Electronic Control Module (ECM)

[80B] Manifold Absolute Pressure Sensor

[88B] Throttle Position Sensor

[83B] Ignition Coil

[89B] Intake Air Temperature Sensor

[84B] Front Injector

[90B] Engine Temperature Sensor

[83B]

[85B] Rear Injector

[91A] Data Link

[87B] Idle Air Control

[119B] EFI Fuse Block

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Figure 8-190. EFI Wire Harness Connectors

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HOME

16. Verify that protective plug is installed in data link connec-

tor [91]. With the plug side down and in contact with tab,

A = Anchored

position connector between arms on electrical bracket.

Frame

17. Tighten five cable straps securing EFI wire harness to

Backbone

right side of frame backbone, upper frame tube and

other wire harness bundles. Cut any excess cable strap

material.

1 A

18. Place battery in battery box, terminal side forward.

Rotate hold-down clamp so that lip (with rubber pad)

rests on edge of battery and tighten clamp bolt.

1WARNING

2 A

Always connect the positive battery cable first. If the

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

3 A

explosion producing personal injury and/or property

damage.

19. Insert bolt through battery positive cable

(red) into

threaded hole of battery positive (+) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

4 A

Saddlebag

20. See Section

9.4 FUEL TANK

(FUEL INJECTED),

Guard

INSTALLATION

(AFTER COMPLETE REMOVAL),

FLHT/C/U/I, FLTRI, or FLHR/C/S/I

21. Install backplate and air cleaner. See Section 4.5 AIR

CLEANER, INSTALLATION.

f2225x8x

22. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

1

Captures EFI harness only (front injector, idle air control

and ignition coil conduit). ANCHORED.

23. Install right side saddlebag. See Section 2.25 SADDLE-

2

3

4 Captures main harness, audio harness (FLHTCUI only),

BAG, INSTALLATION.

EFI harness and conduit to fuel tank harness (all models

except FLHR/C/S). ANCHORED.

24. Start vehicle and verify proper operation without setting

trouble codes.

Figure 8-191. Remove/Install Cable Straps

8-154

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SPECIFICATIONS

9.1

EFI FUSES

TORQUE VALUES

Fuel Pump

15

Blue

Blade

Item

ft/in-lbs

Nm

ECM Power

15

Blue

Blade

Battery hold-down clamp

15-20 ft-lbs

20-27 Nm

TORX bolt

Battery cable bolt

60-96 in-lbs

6.8-10.9 Nm

ECM socket screws

50-60 in-lbs

5.7-6.8 Nm

EFI System

Relay

Electrical bracket flange

Spare

36-48 in-lbs

4.1-5.4 Nm

nuts

Crank position

90-120 in-lbs

10.2-13.6 Nm

Fuel Pump

sensor screw

Engine temperature

120-180 in-lbs

13.6-20.3 Nm

sensor

Fuel tank rear mounting

ECM Power

15-20 ft-lbs

20-27 Nm

bolt

f2223x9x

Fuel tank front mounting

15-20 ft-lbs

20-27 Nm

bolts

Fuel tank canopy TORX

18-24 in-lbs

2.0-2.7 Nm

Figure 9-1. EFI Fuses (Under Right Side Cover)

screws

Fuel level sender TORX

25-35 in-lbs

2.8-4.0 Nm

screw

Fuel supply line

22-26 ft-lbs

29.8-35.3 Nm

quick-connect fitting

Fairing lower U-bolt

35-40 in-lbs

4.0-4.5 Nm

retainer locknuts

Fairing lower cap screws

10-15 in-lbs

1.1-1.7 Nm

Intake manifold to throttle

27-33 in-lbs

3.1-3.7 Nm

body TORX screws

Intake flange adapter

96-144 in-lbs

10.9-16.3 Nm

screws

Exhaust flange adapter

100-120 in-lbs

11.3-13.6 Nm

nuts

Fuel rail TORX screws

27-33 in-lbs

3.0-3.7 Nm

Fuel supply tube clamp

27-33 in-lbs

3.0-3.7 Nm

TORX screw

Intake air temperature

12 in-lbs

1.4 Nm

sensor TORX screws

Throttle position sensor

27-33 in-lbs

3.0-3.7 Nm

TORX screws

Throttle cable bracket

27-33 in-lbs

3.0-3.7 Nm

side TORX screw

Idle air control flange

25 in-lbs

2.8 Nm

screws

Console mounting bolt

50-90 in-lbs

5.7-10.2 Nm

acorn nut

2005 Touring: Fuel Injection

9-1

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ELECTRICAL BRACKET ASSEMBLY

9.2

GENERAL

DATA LINK CONNECTOR

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

SETTING ENGINE IDLE SPEED

beneath the side cover on the right side of the vehicle. The

electrical bracket assembly carries the following components:

NOTE

● Data Link Connector

Engine idle speed can only be set using DIGITAL TECHNI-

CIAN (Part No. HD-44750). Do not tamper with the throttle

● Main Harness to EFI Harness Connector

stop screw as it will not permanently change idle speed.

● ECM Power Fuse/Fuel Pump Fuse

1.

Turn the ignition/light key switch to OFF.

● EFI System Relay

2.

Remove right side saddlebag. See Section 2.25 SAD-

● Electronic Control Module (ECM)

DLEBAG, REMOVAL.

● Vehicle Speed Sensor Connector

3.

Gently pull side cover from frame downtubes (no tools

● Optional Security Siren Connector

required).

2

1

6,7

5

3

4

f1917x9x

1.

Data Link Connector [91]

2.

Main Harness Connector [8]

5.

Electronic Control Module (ECM)

3.

Fuse Block (ECM Power Fuse, Fuel Pump

6.

Vehicle Speed Sensor Connector [65]

Fuse, EFI System Relay)

(Under Bracket)

4.

Electronic Control Module Connector [78]

7.

P&A Security Siren Connector [142] (Under Bracket)

Figure 9-2. Electrical Bracket Assembly

2005 Touring: Fuel Injection

9-3

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INSTALLATION

EFI System Relay

1. Install relay in slots of fuse block. See Figure 9-3.

2. Engage tabs on fuse block with slots in bracket. Slide

Spare

fuse block up into cavity. Gently tug on conduit to verify

that fuse block is locked in place.

3. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

Fuel

Pump

4. Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

f2223x9x

ECM Power

EFI FUSES

REMOVAL

Figure 9-3. EFI Fuse Block

1. Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

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

4.

Gently pull on data link connector [91] to disengage from

required).

arms on electrical bracket. See Figure 9-2.

3. Locate painted white dot on inboard side of fuse block.

5.

Remove rubber protective plug from data link connector.

Pressing on dot, gently tug on conduit to release tabs on

fuse block from slots in bracket.

6.

See DIGITAL TECHNICIAN (Part No. HD-44750) or the

TOURING MODELS ELECTRICAL DIAGNOSTIC MAN-

4. Pull fuses from slots in fuse block and inspect for dam-

UAL to use the data link connector for system diagnosis

age. Replace fuse if the element is burned or broken.

and electrical troubleshooting.

Automotive type ATO fuses are used. See Figure 9-3.

7.

Install protective plug in data link connector.

NOTE

While a spare 15 amp fuse is located in the EFI fuse block,

8.

With the plug side down and in contact with tab, position

one extra 10 amp and 15 amp fuse are also located in the

connector between arms on electrical bracket.

system fuse block cover. See Section 8.3 SYSTEM FUSES

9.

Align barbed studs in side cover with grommets in frame

for more information.

downtubes and push firmly into place

(no tools

required).

INSTALLATION

10.

Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

1.

Insert fuse in the appropriate slot. See Figure 9-3.

2.

Engage tabs on fuse block with slots in bracket. Slide

fuse block up into cavity. Gently tug on conduit to verify

that fuse block is locked in place.

EFI SYSTEM RELAY

3.

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

REMOVAL

4.

Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

1. Remove right side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

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

ELECTRONIC CONTROL MODULE

required).

3. Locate painted white dot on inboard side of fuse block.

Pressing on dot, gently tug on conduit to release tabs on

REMOVAL

fuse block from slots in bracket.

1.

Remove right side saddlebag. See Section 2.25 SAD-

4. Pull relay from slots in fuse block. See Figure 9-3.

DLEBAG, REMOVAL.

9-4

2005 Touring: Fuel Injection

HOME

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

required).

f2183x8x

3. Depress external latch and use rocking motion to

remove ECM connector [78]. See Figure 9-2.

4. Remove two socket screws to detach ECM from electri-

cal bracket.

1

INSTALLATION

1. Align holes in ECM with those in electrical bracket.

Install two socket screws and tighten to 50-60 in-lbs

(5.7-6.8 Nm). See Figure 9-2.

2. Install ECM connector

[78]. Push connector halves

together until latch clicks.

2

3. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

1. Vehicle Speed Sensor [65]

4. Install right side saddlebag. See Section 2.25 SADDLE-

2. P&A Security Siren [142]

BAG, INSTALLATION.

Figure 9-4. Electrical Bracket (Inboard Side)

SECURITY SIREN CONNECTOR

EFI HARNESS

REMOVAL

For removal and installation instructions, see Section 8.32

1. Remove right side saddlebag. See Section 2.25 SAD-

WIRING HARNESSES

AND

CABLES,

EFI

HARNESS

DLEBAG, REMOVAL.

(FUEL INJECTED).

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

required).

3. Remove two flange nuts to release electrical bracket

from studs on side of battery box. See Figure 9-4.

INSTALLATION

1. Install security siren connector [142] and vehicle speed

sensor connector

[65] on inboard side of electrical

bracket as shown in Figure 9-4. Be sure that conduit and

cables are properly routed or wires may be pinched dur-

ing installation.

2.

Slide electrical bracket onto studs at side of battery box.

3. Install flange nuts on studs and tighten to 36-48 in-lbs

(4.1-5.4 Nm).

4. Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

5. Install right side saddlebag. See Section 2.25 SADDLE-

BAG, INSTALLATION.

2005 Touring: Fuel Injection

9-5

HOME

SENSORS

9.3

GENERAL

f2256x8x

Six sensors inform the ECM of the environmental and engine

operating factors influencing fuel and spark requirements.

The sensors are as follows:

● Intake Air Temperature Sensor

● Throttle Position Sensor

● Manifold Absolute Pressure Sensor

● Bank Angle Sensor (Internal to TSM/TSSM)

● Crankshaft Position Sensor

● Engine Temperature Sensor

Stator

INTAKE AIR TEMPERATURE SENSOR

Connector [46]

See Section

9.5 INDUCTION MODULE ASSEMBLY,

Crankshaft

Position Sensor

INTAKE AIR TEMPERATURE SENSOR.

Connector [79]

THROTTLE POSITION SENSOR

Figure 9-5. Voltage Regulator (Left Side View)

See Section

9.5 INDUCTION MODULE ASSEMBLY,

THROTTLE POSITION SENSOR.

f2217x8x

MANIFOLD ABSOLUTE PRESSURE

Socket Screw

SENSOR

See Section 9.5 INDUCTION MODULE ASSEMBLY, MANI-

FOLD ABSOLUTE PRESSURE SENSOR.

BANK ANGLE SENSOR

See Section 8.17 TURN SIGNAL/SECURITY MODULE.

CRANKSHAFT POSITION SENSOR

REMOVAL

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

Figure 9-6. Remove Sensor Mount Socket Screw

2.

Locate crankshaft position sensor connector

[79],

2-

place Mini-Deutsch, fixed to bracket at bottom of voltage

regulator. See Figure 9-5.

5.

Remove allen head socket screw to free crankshaft posi-

3.

Push connector toward right side of motorcycle to disen-

tion sensor mount from front left side of crankcase. Pull

gage small end of slot on attachment clip from T-stud on

sensor from bore. See Figure 9-6.

bracket. Lift connector off T-stud.

6.

Pull sensor to draw convoluted tubing and connector out

4.

Depress button on socket terminal side and pull apart

from under voltage regulator.

pin and socket halves.

9-6

2005 Touring: Fuel Injection

HOME

INSTALLATION

O-Ring

1. Hand start threaded end of new temperature sensor into

cylinder head bore.

2. Slide 3/4 inch deepwell socket over sensor body hex and

tighten to 120-180 in-lbs (13.6-20.3 Nm).

3. Install engine temperature sensor connector

[90],

2-

place Packard, at back of front cylinder.

4. Pull boot over sensor to keep out dirt and debris.

5. Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

f2321x8x

MAXI-FUSE, INSTALLATION.

Figure 9-7. Crankshaft Position Sensor

Sensor

Body Hex

INSTALLATION

Thermistor

1. Install new O-ring on sensor body if missing, distorted,

pinched or otherwise damaged. Apply a thin film of clean

H-D 20W50 engine oil to O-ring before installation.

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

hole in spot face. Install allen head socket screw and

tighten to 90-120 in-lbs (10.2-13.6 Nm). See Figure 9-6.

3. Route connector and convoluted tubing under front

f1699x9x

engine stabilizer link to underside of voltage regulator.

4. Mate pin and socket halves of crankshaft position sensor

Figure 9-8. Engine Temperature Sensor

connector [79]. See Figure 9-5.

5. Place large end of slot on attachment clip over T-stud on

bracket. Push connector toward left side of motorcycle to

engage small end of slot.

6. Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

ENGINE TEMPERATURE SENSOR

REMOVAL

1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2. On left side of motorcycle, pull back boot at back of front

cylinder to reveal engine temperature sensor connector

[90], 2-place Packard.

3. Pull external latch outward and use rocking motion to

remove connector.

4. Slide a 3/4 inch deepwell socket over the sensor body

hex and turn counter-clockwise to loosen. See Figure 9-

8. When sensor turns easily, pull out the deepwell socket

and remove sensor by hand.

2005 Touring: Fuel Injection

9-7

HOME

FUEL TANK (FUEL INJECTED)

9.4

● Fuel Filter Canister

GENERAL

● Fuel Level Sender

See Figure 9-9. The fuel pump, fuel filter canister, fuel pres-

● Fuel Supply Check Valve

sure regulator, and fuel level sender are attached to the can-

opy for easy removal and installation. The act of raising the

canopy automatically removes these items, thereby eliminat-

ing those tasks which used to be performed by reaching

COMPLETE REMOVAL

inside the fuel tank. This arrangement minimizes the possibil-

ity of dropping or losing parts inside the tank, or adding con-

taminants (such as grease and oil) to the fuel supply.

FLHT/C/U/I, FLTRI

The fuel tank assembly consists of the following components:

● Fuel Tank

1WARNING

● Canopy

Gasoline is extremely flammable and highly explosive.

● Fuel Pump

When servicing the fuel system, do not smoke or allow

● Fuel Pressure Regulator

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

Canopy

Fuel Filter

Canister

Fuel Level

Sender

Fuel Pressure

and Float

Regulator

In-tank Tubing

(Fuel Pressure Regulator

to Supply Fitting)

Fuel Pump

In-tank Tubing

Supply Fitting

(Fuel Pump to Filter Canister)

f1969x9x

(Check Valve)

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

9-8

2005 Touring: Fuel Injection

HOME

a. Remove the 15 amp fuel pump fuse. See Figure 9-

10. If necessary, see Section

9.2 ELECTRICAL

BRACKET ASSEMBLY, EFI FUSES, REMOVAL.

b. Start the engine and allow the vehicle to run.

c. When the engine stalls, operate starter for 3 sec-

onds to remove remaining fuel from fuel lines.

Fuel

1WARNING

Pump

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

4.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

f2223x9x

5.

Carefully cut anchored cable strap securing main har-

Figure 9-10. EFI Fuse Block

ness bundles, console pod conduit (Ultra models only),

fuel level sender/fuel pump conduit, and fuel vapor vent

tube to left side of frame backbone.

1WARNING

6.

Open fuel door on console. Remove two Allen head

screws inboard of rubber bumpers. These screws secure

Gasoline will drain from the crossover hose when dis-

console to clip nuts on the canopy bracket.

connected from the fuel tank. Thoroughly wipe up any

7.

Remove Allen head screw to detach flange at rear of

spilled fuel immediately. Dispose of rags in a suitable

console from clip nut on fuel tank weldment.

manner. Gasoline is extremely flammable and highly

explosive. Inadequate safety precautions could result in

8.

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

death or serious injury.

9.

Remove filler cap from neck of fuel tank. Remove con-

sole and lay upside down on shop towel. Reinstall filler

cap.

CAUTION

10. Depress button on socket side and remove fuel level

Do not kink crossover hose or crimp shut using pliers or

sender/fuel pump connector [141], 3-place Mini-Deut-

similar tool. Damage to the rigid inner lining will occur.

sch, at top of canopy.

1. Drain fuel tank as follows:

11. Gently pry fuel vapor vent tube from fitting on filler neck

of fuel tank. Exercise caution to avoid pulling fitting from

Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D.

filler neck.

Insert bolt in one end of hose and install hose clamp to

ensure that end is securely plugged. Using a side cutters, cut

clamp from one end of crossover hose beneath fuel tank.

1WARNING

Quickly replace crossover hose on fuel tank fitting with open

end of short hose while directing flow of gasoline from free

A small amount of gasoline may drain from the fuel sup-

end of crossover hose into suitable container.

ply line when disconnected from the fuel tank. Thor-

oughly wipe up any spilled fuel immediately. Dispose of

2. Remove seat. See Section 2.24 SEAT, REMOVAL.

rags in a suitable manner. Gasoline is extremely flamma-

ble and highly explosive. Inadequate safety precautions

could result in death or serious injury.

1WARNING

The gasoline in the fuel supply line downstream of the

1WARNING

fuel pump is under high pressure (58 psi). To avoid an

uncontrolled discharge or spray of gasoline, always

Exercise caution to avoid twisting the fuel supply line fit-

purge the system of high pressure gas before the fuel

ting, as any cracks in the plastic construction of the line

supply line is disconnected. Gasoline is extremely flam-

can result in gas leaks. Gas leakage can cause fire or

mable and highly explosive. Inadequate safety precau-

explosion which could result in death or serious injury.

tions could result in death or serious injury.

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

3. Purge the fuel supply line of high pressure gas. Proceed

up on chrome sleeve and pull down on fuel supply line

as follows:

fitting to disconnect. See Figure 9-11.

2005 Touring: Fuel Injection

9-9

HOME

f2021x9x

Fuel

CAUTION

Tank

When removing instrument console, exercise caution to

avoid damaging speedometer unit. Wrap console in a

clean, dry shop towel to prevent damage.

6.

Secure instrument console to top of rear fender using

Chrome

bungee cords.

Sleeve

7.

Remove console mounting bolt from slot at top of can-

opy.

8.

Gently pry fuel vapor vent tube from fitting.

9.

At bottom left side of fuel tank, gently pull on convoluted

tubing to draw fuel gauge connector [117], 4-place Mul-

tilock, out of tunnel. Depress button on socket terminal

side and pull apart pin and socket halves.

1WARNING

Figure 9-11. Fuel Supply Line Fitting

A small amount of gasoline may drain from the fuel sup-

ply line when disconnected from the fuel tank. Thor-

oughly wipe up any spilled fuel immediately. Dispose of

13. Remove two fuel tank front mounting bolts (with flat

rags in a suitable manner. Gasoline is extremely flamma-

washers) from left and right side of frame. Remove bolt

ble and highly explosive. Inadequate safety precautions

(with flat washer) to free rear of fuel tank from frame

could result in death or serious injury.

backbone.

NOTE

1WARNING

The fuel tank mounting bolts have both an internal TORX

recess and an external hex, which allows them to be

Exercise caution to avoid twisting the fuel supply line fit-

removed with either a T40 TORX bit or a 1/2 inch open end/

ting, as any cracks in the plastic construction of the line

box wrench. Use of the external hex allows the front mount-

can result in gas leaks. Gas leakage can cause fire or

ing bolts to be removed without having to loosen or remove

explosion which could result in death or serious injury.

the fairing lowers, if installed.

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

14. Remove fuel tank from vehicle.

up on chrome sleeve and pull down on fuel supply line

fitting to disconnect. See Figure 9-11.

11. Remove fuel tank from vehicle.

FLHR/C/S/I

1.

See Section 9.4 FUEL TANK (FUEL INJECTED), COM-

INSTALLATION

PLETE REMOVAL, FLHT/C/U/I, FLTRI, steps 1-4.

(AFTER COMPLETE REMOVAL)

2.

Remove two fuel tank front mounting bolts (with flat

washers) from left and right side of frame. Remove bolt

(with flat washer) to free rear of fuel tank from frame

FLHT/C/U/I, FLTRI

backbone. On FLHRSI models, removal of rear bolt also

releases instrument console bracket.

CAUTION

3.

Carefully cut anchored cable strap securing main har-

ness bundle, instrument console conduit, and fuel vapor

Exercise caution to avoid pinching the wiring harness

vent tube to left side of frame backbone.

between the fuel tank and vehicle frame. Wire damage

may result in electrical problems.

4.

Remove acorn nut from instrument console. If present,

also remove Phillips screw and large flat washer (absent

1.

Work fuel tank into position aligning front flange holes

on FLHRSI models).

with those in frame.

5.

Raise instrument console and bend back flexible clamp

2.

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

on canopy to release main harness conduit. Depress

ning hose beneath frame backbone, install hose onto fit-

button on socket side and remove fuel level sender/fuel

ting at bottom front of fuel tank

(after removing

pump connector [141], 3-place Mini-Deutsch.

temporary plug). Crimp clamp.

9-10

2005 Touring: Fuel Injection

HOME

3.

Start fuel tank front mounting bolts (with flat washers)

f2007x9x

into left and right side of frame.

Console

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

Pod

frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).

Fuel

Tank

5.

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

27 Nm).

1WARNING

Fuel Pump,

Fuel Level

Exercise caution to avoid twisting the fuel supply line fit-

Sender Conduit

ting, as any cracks in the plastic construction of the line

can result in gas leaks. Gas leakage can cause fire or

explosion which could result in death or serious injury.

Fuel

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

Main

Overflow

up on chrome sleeve and insert neck of fuel supply line

Harness

Fuel Vapor

Hose

fitting. While pushing up on bottom of fitting, pull down

Bundle

Vent Tube

(To Vapor Valve)

on chrome sleeve until it “clicks” into the locked position.

1WARNING

Main

To avoid an uncontrolled discharge or spray of gasoline,

Anchored

Harness

always be sure the quick-connect fitting is properly

Console

Cable Strap

Bundle

mated. A slight tug on the fuel supply line fitting will ver-

Pod Conduit

ify this condition. Gasoline is extremely flammable and

highly explosive. Inadequate safety precautions could

FLHTCUI

result in death or serious injury.

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

f1739b9x

fuel tank.

Fuel

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

Tank

place Mini-Deutsch, at top of canopy.

Console

9. Remove filler cap. Position console on canopy. Route

cables from beneath console as shown in Figure 9-12.

Be sure that hoses and wires are not pinched by the

console during installation. Reinstall filler cap.

Fuel Pump,

Fuel Level

10. Install Allen head screw to fasten rear flange of console

Sender Conduit

to clip nut on fuel tank weldment. Tighten screw to 25-30

in-lbs (2.8-3.4 Nm).

11. Open fuel door on console. Install two Allen head screws

Fuel

to secure front of console to clip nuts on canopy bracket.

Overflow

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).

Fuel Vapor

Hose

Vent Tube

12. Snap anchor of new cable strap into hole on left side of

(To Vapor Valve)

frame backbone. Tighten cable strap capturing main har-

ness bundles, console pod conduit (Ultra models only),

Main

fuel level sender/fuel pump conduit, and fuel vapor vent

Harness

tube. See Figure 9-12. Cut any excess cable strap mate-

Bundle

rial.

Anchored

Main

Cable Strap

Harness

NOTE

Bundle

Route fuel overflow hose inboard of wire bundles on right

side of frame, but do not capture in cable straps.

FLHT/C/I, FLTRI

13. Insert bolt through battery negative cable (black) into

Figure 9-12. Console Pod Cable/Hose Routing

threaded hole of battery negative (-) terminal. Tighten

(Top View)

bolt to 60-96 in-lbs (6.8-10.9 Nm).

2005 Touring: Fuel Injection

9-11

HOME

14. Install the 15 amp fuel pump fuse. See Figure 9-10. If

necessary, see Section 9.2 ELECTRICAL BRACKET

ASSEMBLY, EFI FUSES, INSTALLATION.

Convoluted

15. Install seat. See Section 2.24 SEAT, INSTALLATION.

Tubing

FLHR/C/S/I

1. Work fuel tank into position aligning front flange holes

with those in frame.

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

ning hose beneath frame backbone, install hose onto fit-

8870

ting at bottom front of fuel tank

(after removing

temporary plug). Crimp clamp.

Figure 9-13. Fuel Gauge (FLHR/C/S)

1WARNING

11.

Install acorn nut at top of instrument console and tighten

Exercise caution to avoid twisting the fuel supply line fit-

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install

ting, as any cracks in the plastic construction of the line

Phillips screw and large flat washer (absent on FLHRSI

can result in gas leaks. Gas leakage can cause fire or

models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

explosion which could result in death or serious injury.

12.

Connect fuel gauge to main harness. Route pin housing

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

and convoluted tubing forward and then inboard

up on chrome sleeve and insert neck of fuel supply line

between front of crossover hose fitting and bottom of fuel

fitting. While pushing up on bottom of fitting, pull down

tank. Mate pin and socket halves of fuel gauge connec-

on chrome sleeve until it “clicks” into the locked position.

tor [117], 4-place Multilock. Feed connector into tunnel

of fuel tank. See Figure 9-13.

13.

Snap anchor of new cable strap into hole on left side of

1WARNING

frame backbone. Tighten cable strap capturing main har-

To avoid an uncontrolled discharge or spray of gasoline,

ness bundle, instrument console conduit, and fuel vapor

always be sure the quick-connect fitting is properly

vent tube. Cut any excess cable strap material. See Fig-

mated. A slight tug on the fuel supply line fitting will ver-

ure 9-12.

ify this condition. Gasoline is extremely flammable and

14.

Insert bolt through battery negative cable (black) into

highly explosive. Inadequate safety precautions could

threaded hole of battery negative (-) terminal. Tighten

result in death or serious injury.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

4. Connect fuel vapor vent tube to fitting at top of canopy.

15.

Install the 15 amp fuel pump fuse. See Figure 9-10. If

necessary, see Section 9.2 ELECTRICAL BRACKET

5. Slide head of console mounting bolt into slot at top of

ASSEMBLY, EFI FUSES, INSTALLATION.

canopy.

16.

Install seat. See Section 2.24 SEAT, INSTALLATION.

6. Moving instrument console toward installed position,

install fuel level sender/fuel pump connector [141], 3-

place Mini-Deutsch, at top of canopy. Bend flexible

clamp to capture main harness conduit.

PARTIAL REMOVAL

7. Align hole in instrument console with console mounting

bolt and place into position on fuel tank.

FLHT/C/U/I, FLTRI

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

into left and right side of frame.

1WARNING

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

frame backbone. On FLHRSI models, capture instru-

Gasoline is extremely flammable and highly explosive.

ment console bracket during installation. Tighten bolt to

When servicing the fuel system, do not smoke or allow

15-20 ft-lbs (20-27 Nm).

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

10. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

27 Nm).

1.

Remove seat. See Section 2.24 SEAT, REMOVAL.

9-12

2005 Touring: Fuel Injection

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