Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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280

CHAPTER SEVEN

dle extending out of the bottom of the vacuum pis-

ton.

6. Remove the float bowl as follows:

a. Remove the screws (Figure 29) securing the

float bowl to the carburetor.

b. Slowly remove the float bowl body and with-

draw the pump rod (Figure 30) from the boot

on the bowl.

c. Disconnect the pump rod from the lever as-

sembly on the carburetor (Figure 31).

NOTE

One of the float pin pedestals has an

interference fit that holds the float pin

in place. An arrow, (Figure 32) cast

into the carburetor, points to this ped-

estal. To remove this float pin, tap it

out from the interference side in the

direction of the arrow.

CAUTION

If the float pin is removed in the direc-

tion opposite of the arrow, the oppo-

site pedestal may crack or break off. If

this occurs the carburetor must be re-

placed.

7. Carefully tap the float pin (Figure 33) out of the

pedestals and remove it.

8. Remove the float and needle valve assembly

(Figure 34).

9. Unscrew and remove the pilot jet (Figure 35).

10. Unscrew and remove the main jet (Figure

36).

11. Unscrew and remove the needle jet holder (Fig-

ure 37).

12. Remove the needle jet (A, Figure 38) from the

needle jet bore in the carburetor.

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FUEL, EXHAUST AND EMISSION SYSTEMS

281

Cleaning and Inspection

Replace worn or damaged parts as described in

this section.

CAUTION

The carburetor body is equipped with

plastic parts that cannot be removed.

Do not dip the carburetor body,

O-rings, float assembly, needle valve

or vacuum piston in a carburetor

cleaner or other harsh solution that

can damage these parts. The use of a

caustic carburetor cleaning solvent is

not recommended. Instead, clean the

carburetor and related parts in a pe-

troleum-based solvent, or Simple

Green. Then rinse in clean water.

1. Initially clean all parts in a mild petroleum based

cleaning solution. Then clean in hot soap and water

and rinse with cold water. Blow dry with com-

pressed air.

CAUTION

If compressed air is not available, al-

low the parts to air dry or use a clean

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282

CHAPTER SEVEN

lint-free cloth. Do not use a paper

towel to dry carburetor parts, as

small paper particles may plug open-

ings in the carburetor housing or jets.

2. Allow the carburetor to dry thoroughly before

assembly and blow dry with compressed air. Blow

out the jets and the needle jet holder with com-

pressed air.

CAUTION

Do not use wire or drill bits to clean

jets as minor gouges in the jet can al-

ter flow rate and upset the air/fuel

mixture.

3. Inspect the float bowl O-ring gasket (A, Figure

39) for hardness or deterioration.

4. Inspect the accelerator pump boot (B, Figure

39) for hardness or deterioration.

5. Make sure the accelerator pump cover (Figure

40) screws are tight.

6. Inspect the vacuum piston diaphragm (Figure

41) for cracks, deterioration or other damage.

Check the vacuum piston sides (Figure 42) for ex-

cessive wear. Install the vacuum piston into the car-

buretor body and move it up and down in the bore.

The vacuum piston should move smoothly with no

binding or excessive play. If there is excessive play,

the vacuum piston slide and/or carburetor body

must be replaced.

7. Inspect the needle valve tapered end for steps,

uneven wear or other damage (Figure 43).

8. Inspect the needle valve seat (B, Figure 38) for

steps, uneven wear or other damage. Insert the nee-

dle valve and slowly move it back and forth and

check for smooth operation. If either part is worn or

damaged, replace both parts as a pair for maximum

performance.

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FUEL, EXHAUST AND EMISSION SYSTEMS

283

9. Inspect the needle jet holder, pilot jet and main

jet (Figure 44). Make sure all holes are open and

none of the parts are either worn or damaged.

10. Inspect the jet needle, spring and spring seat

(Figure 45) for deterioration or damage.

11. Inspect the jet needle tapered end for steps, un-

even wear or other damage.

12. Inspect the float (Figure 46) for deterioration

or damage. If the float is suspected of leakage, place

it in a container of water and push it down. If the

float sinks or if bubbles appear (indicating a leak),

the float must be replaced.

13. Make sure the throttle plate (Figure 47) screws

are tight. Tighten if necessary.

14. Move the throttle wheel (Figure 48) back and

forth from stop to stop and check for free move-

ment. The throttle lever should move smoothly and

return under spring tension.

15. Check the throttle wheel return spring (Figure

49) for free movement. Make sure it rotates the

throttle wheel back to the stop position with no hesi-

tation.

16. Make sure all openings in the carburetor hous-

ing are clear. Clean out if they are plugged in any

way, then apply compressed air to all openings.

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284

CHAPTER SEVEN

17. Inspect the carburetor body for internal or ex-

ternal damage. If damaged, replace the carburetor

assembly, as the body cannot be replaced sepa-

rately.

18. Check the top cover for cracks or damage.

19. Check the starting enrichment valve and cable

as follows:

a. Check the end of the valve (Figure 50) for

damage.

b. Check the entire length of the cable for bends,

chafing or other damage.

c. Check the knob, nut and lock washer for dam-

age. Move the knob and check for ease of

movement.

Assembly

NOTE

The needle jet has two different sides

and must be installed correctly as de-

scribed in Step 1.

1. Position the needle jet with the long end going in

first (Figure 51) and install it (A, Figure 38).

2. Install the needle jet holder (Figure 37) into the

main jet passage. Make sure it passes through the

opening in the venturi (Figure 52), then tighten se-

curely.

3. Install the main jet and tighten securely (Figure

36).

4. Install the pilot jet and tighten securely (Figure

35).

5. Install the fuel valve onto the float (Figure 53)

and position the float onto the carburetor so that the

valve drops into its seat.

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FUEL, EXHAUST AND EMISSION SYSTEMS

285

CAUTION

The pedestals that support the float

pin are fragile. In the next step, sup-

port the pedestal on the arrow side

while tapping the float pin into place.

6. Align the float pin with the two pedestals.

7. Install the float pin (A, Figure 54) from the side

opposite the arrow (B, Figure 54). Support the ped-

estal and tap the float pin into place in the pedestal.

8. Check the float level as described in this chapter.

9. Install the float bowl as follows:

a. Make sure the float bowl O-ring seal (A, Fig-

ure 39) and accelerator rod boot (B) are in

place.

b. Connect the pump rod onto the lever assem-

bly on the carburetor (Figure 55).

c. Slowly install the float bowl body and insert

the accelerator pump rod through the boot

(Figure 30) on the float bowl. Engage the rod

with the diaphragm while installing the float

bowl.

d. Install the float bowl and screws (Figure 29)

and tighten the screws securely in a crisscross

pattern.

10. Insert the jet needle (Figure 56) through the

center hole in the vacuum piston.

11. Install the spring seat (A, Figure 57) and spring

(B) over the top of the needle to secure it in place.

12. Align the slides (A, Figure 58) on the vacuum

piston with the grooves (B) in the carburetor bore

and install the vacuum piston (B, Figure 28). The

slides on the piston are offset, so the piston can only

be installed one way. When installing the vacuum

piston, make sure the jet needle drops through the

needle jet.

13. Seat the outer edge of the vacuum piston dia-

phragm into the piston chamber groove (Figure 59).

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286

CHAPTER SEVEN

FLOAT BASE POSITION

Carburetor

Float

14. Align the free end of the spring with the carbu-

retor top and install the top onto the carburetor.

15. Hold the carburetor top in place and lift the vac-

uum piston with a finger (Figure 60). The piston

must move smoothly. If the piston movement is

rough or sluggish, the spring is installed incorrectly.

Remove the carburetor top and reinstall the spring.

16. Install the carburetor top three screws (Figure

FLOAT ADJUSTMENT

27) finger-tight.

POSITION

17. Install the collar (Figure 26) into the cover.

18. Install the throttle cable bracket (B, Figure 25)

Carburetor

onto the carburetor so that the end of the idle speed

screw engages the top of the throttle cam stop (B,

Figure 24). Hold the bracket in place and install the

bracket’s side mounting screw and washer (A, Fig-

ure 24). Tighten the screw securely.

Float

19. Install the top screw (A, Figure 25) and tighten

securely.

20. Install the starting enrichment cable and valve

0.413-0.453 in.

into the carburetor body and tighten the nut securely

(10.5-11.5 mm)

(Figure 23).

15° to 20°

Float Adjustment

The carburetor must be removed and partially

disassembled for this adjustment.

1. Remove the carburetor as described in this chap-

ter.

2. Remove the float bowl as described in this chap-

ter.

3. Place the engine manifold side of the carburetor

on a clean flat surface as shown in Figure 61. This

is the base position.

4. Tilt the carburetor upward 15-20° as shown in

Figure 62. At this position, the float will come to

rest without compressing the pin return spring.

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FUEL, EXHAUST AND EMISSION SYSTEMS

287

INTAKE MANIFOLD

1. Manifold seal

2. Flange

3. Intake manifold

4. Screw

5. Clip

6. MAP sensor

7. Seal

8. Bolt

9. Seal ring

NOTE

9. Repeat these steps until the float level is correct.

If the carburetor is tilted less than 15°

10. Install the float bowl and carburetor as de-

or more than 20°, the float measure-

scribed in this chapter.

ment will be incorrect.

5. Measure from the carburetor flange surface to

INTAKE MANIFOLD

the top of the float as shown in Figure 62. When

measuring float level, do not compress the float.

Removal/Installation

The correct float level measurement is 0.413-0.453

in. (10.5-11.5 mm).

Refer to Figure 64.

6. If the float level is incorrect, remove the float pin

1. Remove the carburetor as described in this chap-

and float as described under Carburetor Disassem-

ter.

bly in this chapter.

NOTE

7. Slowly bend the float tang (Figure 63) with a

The front and rear intake manifold

screwdriver and adjust to the correct position.

flanges are different. If the flanges are

8. Reinstall the float and the float pin as described

not marked, label them with an F and

under Carburetor Assembly in this chapter. Re-

R so they will be reinstalled in the cor-

check the float level.

rect location.

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288

CHAPTER SEVEN

2. Disconnect the electrical connector from the

MAP sensor (A, Figure 65) on top of the intake

manifold.

NOTE

Figure 65 shows only two of the Allen

bolts. Remove all four bolts.

3. Remove the four Allen bolts (B, Figure 65) se-

curing the intake manifold to the cylinder heads.

4. Remove the intake manifold, flanges and mani-

fold seals.

5. Inspect the intake manifold as described in this

section.

6. Install the flanges and manifold seals (Figure

66) onto the intake manifold.

7. Install the intake manifold onto the cylinder

head intake ports.

8. Check that the front and rear seals seat squarely

against the cylinder head mating surfaces.

9. Install all four Allen bolts finger-tight at this

time.

10. Temporarily install the carburetor into the in-

take manifold.

CAUTION

Do not attempt to align the intake

manifold after tightening the bolts.

This will damage the manifold seals.

If necessary, loosen the bolts, then

align the manifold.

11. Check that the intake manifold seats squarely

against the cylinder heads. Then check that the car-

buretor seats squarely in the intake manifold. Re-

move the carburetor.

NOTE

It is very difficult to get an Allen

wrench and torque wrench onto the

14. Connect the electrical connector onto the MAP

two inboard Allen bolts to tighten

them to a specific torque value.

sensor (A, Figure 65).

Tighten the outboard Allen bolts to the

15. Install the carburetor as described in this chap-

specified torque value, then tighten

ter.

the inboard Allen bolts to the same

approximate tightness.

Inspection

12. Tighten the intake manifold Allen bolts to the

specification in Table 2.

13. If the MAP sensor was removed, install a new

1. Check the intake manifold seals (Figure 66) for

seal in the manifold receptacle, then install the MAP

wear, deterioration or other damage. Replace the

sensor.

seals as a set if necessary.

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FUEL, EXHAUST AND EMISSION SYSTEMS

289

THROTTLE CABLES

2. Check the intake manifold seal ring (Figure 67)

for cracks, flat spots or other damage. Replace if

necessary.

3. If necessary, remove the self-tapping screw and

clamp and remove the MAP sensor.

THROTTLE AND IDLE

CABLE REPLACEMENT

There are two different throttle cables (Figure

68). One is the throttle control cable (A, Figure 69

and A, Figure 70) and the other is the idle control

cable (B, Figure 69 and B, Figure 70). Figure 68

shows the throttle housing and cable assembly. The

cables are identified as follows:

a. Throttle control cable.

Handlebar

Ferrule

b. Idle cable.

Upper housing

10.

Clip

Lower housing

11.

Throttle grip

NOTE

Friction shoe

12.

Throttle control

The throttle control and idle control

Snap ring

cable

cables have differently sized threads

Spring

13.

Boot

on the cable’s threaded adjusters.

Adjusting screw

14.

Idle control

Screw

cable

The throttle control cable has a

5/16-18 threaded adjuster. The idle

control cable has a 1/4-20 threaded

adjuster.

1. Remove the fuel tank as described in this chap-

ter.

2. Remove the air filter and backing plate as de-

scribed in this chapter.

3. Make a drawing or take a picture of the cable

routing from the carburetor through the frame to the

right side handlebar.

4. At the right side handlebar, perform the follow-

ing:

a. Slide the rubber boot off both cables.

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290

CHAPTER SEVEN

b. Loosen both control cable adjuster locknuts

(A, Figure 71), then turn the cable adjusters

(B, Figure 71) clockwise as far as possible to

increase cable slack.

5. Loosen the cable jam nuts (A, Figure 72) at the

throttle housing.

6. Remove the screws (B, Figure 72) securing the

upper and lower housings to the handlebar, then

separate the housings.

7. Remove the friction pad (Figure 73) from the

lower throttle housing.

8. Unhook the cables (Figure 74) from the throttle

grip and remove the ferrule from the end of each ca-

ble (Figure 75).

9. Pull the crimped inserts at the end of the throttle

and idle control cable housings from the switch

lower housing.

10. Partially remove the carburetor, as described in

this chapter, until the throttle cables can be discon-

nected from the throttle wheel.

11. Disconnect the throttle control cable (A, Fig-

ure 76) and the idle control cable (B) from the car-

buretor cable guide and the throttle wheel (C).

12. Remove the cables from the frame.

13. Clean the throttle grip assembly and dry thor-

oughly. Check the throttle slots for cracks or other

damage. Replace the throttle if necessary.

14. The friction adjust screw is secured to the lower

switch housing with a snap ring. If necessary, re-

move the friction spring, snap ring, spring and fric-

tion adjust screw. Check these parts for wear or

damage. Replace damaged parts and reverse to in-

stall. Make sure the snap ring seats in the friction

screw groove completely.

15. Clean the throttle area on the handlebar with

solvent.

16. Apply a light coat of graphite to the housing in-

side surfaces and to the handlebar.

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FUEL, EXHAUST AND EMISSION SYSTEMS

291

17. On the lower switch housing, push the larger

diameter silver throttle cable insert into the larger

hole in front of the tension adjust screw. Push it in

until it snaps into place.

18. Push the smaller diameter gold throttle cable in-

sert into the smaller hole in the rear of the tension

adjust screw. Push it in until it snaps into place.

19. Install the friction pad (Figure 73) into the

lower housing (Figure 78). Match the curvature on

the friction pad with the handlebar.

20. Install a ferrule (Figure 75) onto the end of

each cable, then insert the ferrules into the throttle

grip slots (Figure 74).

NOTE

If the master cylinder is not mounted on

the handlebar, fit the throttle housing

wiring harness into the depression (Fig-

ure 79) in the bottom of the handlebar.

21. Assemble the upper and lower switch housings

and the throttle grip. Install the lower switch hous-

ing screws (B, Figure 72) and tighten securely. Op-

erate the throttle and make sure both cables move in

and out properly.

22. Route the cables from the handlebar to the car-

buretor.

23. Connect the idle cable (B, Figure 70) to the

carburetor as follows:

a. The idle cable has the small spring (A, Figure

80) on the end of the cable.

b. Insert the idle cable sheath into the rear cable

bracket guide on the carburetor (B, Figure

80).

c. Attach the end of the idle cable into the throt-

tle wheel (C, Figure 80).

24. Connect the throttle cable (A, Figure 70) to the

carburetor as follows:

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292

CHAPTER SEVEN

a. Insert the throttle cable sheath (A, Figure 76)

into the front cable bracket guide on the car-

buretor.

b. Attach the end of the throttle cable into the

throttle wheel (C, Figure 76).

25. Operate the hand throttle a few times, making

sure the throttle wheel operates smoothly with no

binding. Also check that both cable ends are seated

squarely in their cable bracket guides and in the

throttle wheel.

26. Adjust the throttle and idle cables as described

in Chapter Three.

27. Reinstall the carburetor as described in this

2. Note the routing of the enrichener cable from its

chapter.

mounting bracket to the carburetor.

28. Install the air filter backplate and air filter as

3. Loosen the locknut (A, Figure 81) and discon-

described in this chapter.

nect the starting enrichment valve cable to the

29. Install the fuel tank as described in this chapter.

mounting bracket (B). Move the end of the cable out

30. Start the engine and allow it to idle in

of the mounting bracket.

NEUTRAL. Then turn the handlebar from side to

4. Partially remove the carburetor, as described in

side. Do not operate the throttle. If the engine speed

this chapter, until the starting enrichment valve ca-

increases when turning the handlebar assembly, the

ble can be disconnected from the backside of the

throttle cables are routed incorrectly or damaged.

carburetor.

Recheck cable routing and adjustment.

5. Unscrew and remove the starting enrichment

WARNING

valve and cable (Figure 82) from the carburetor and

Do not ride the motorcycle until the

remove the cable from the frame.

throttle cables are properly adjusted.

6. Install by reversing these removal steps while

Improper cable routing and adjustment

can cause the throttle to stick open. This

noting the following:

could cause loss of control. Recheck the

a. Align the starting enrichment valve needle

work before riding the motorcycle.

(A, Figure 83) with the needle passage in

the carburetor (B) and install the starting

enrichment valve. Tighten the valve nut se-

STARTING ENRICHMENT VALVE

curely.

(CHOKE) CABLE REPLACEMENT

b. Position the starting enrichment valve cable

1. Remove the air filter and backplate as described

into the mounting bracket (B, Figure 81),

in Chapter Three.

then tighten the locknut (A) securely.

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FUEL, EXHAUST AND EMISSION SYSTEMS

293

FUEL TANK (FXDP)

1. Screw

2. Ignition switch and key

3. Trim plate

4. Washer

5. Center console

6. Gasket

7. Mounting bracket

8. Nut clip

9. Clip

10. Pop rivet

11. Filler cap

12. Gasket

13. Bolt

14. Acorn nut

15. Fuel tank

16. Hose clamp

17. Interconnecting hose

FUEL TANK

hot part, leaking vapors may ignite,

causing a fire.

WARNING

Some fuel may spill from the fuel tank

Removal/Installation

hose when performing this procedure.

Because gasoline is extremely flam-

The fuel hose is secured to the fuel tank with a

mable and explosive, perform this

non-reusable clamp. If the same type of clamp is go-

procedure away from all open flames

ing to be reinstalled, purchase one before servicing

(including appliance pilot lights) and

sparks. Do not smoke or allow some-

the fuel tank.

one who is smoking in the work area,

Refer to Figure 84, Figure 85 and Figure 86 for

as an explosion and fire may occur.

fuel tank components and lines.

Always work in a well-ventilated

area. Wipe up any spills immediately.

NOTE

On models so equipped, always dis-

WARNING

arm the optional TSSM security sys-

Make sure to route the fuel tank vapor

tem prior to disconnecting the battery

hoses so that they cannot contact any

or the siren will sound.

hot engine or exhaust component.

These hoses contain flammable va-

1. Disconnect the negative battery cable from the

pors. If a hose melts from contacting a

battery.

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294

CHAPTER SEVEN

FUEL TANK (ALL MODELS EXCEPT FXDP)

1. Hose clamp

2. Interconnecting hose

3. Filler cap

4. Gasket

5. Bolt

6. Washer

7. Acorn nut

8. Fuel tank (FXDWG,

FXDL)

9. Boot

10. Fuel tank (FXDS-CON,

FXD, FXDX, FXDXT)

2. Remove the seat as described in Chapter Thir-

a. Connect the drain hose to the fuel valve and

teen.

secure it with a hose clamp. Insert the end of

3. Turn the fuel valve to the OFF position (A, Fig-

the drain hose into a gas can.

ure 87).

b. Disconnect the vacuum hose (Figure 88)

4. Remove the factory hose clamp and disconnect

from the fuel valve.

the fuel hose (B, Figure 87) from the valve.

c. Connect a hand-operated vacuum pump (Fig-

ure 89) to the fuel valve vacuum hose fitting.

NOTE

d. Turn the fuel valve to the RES position.

On some models, a crossover tube

connects the two fuel tanks. Drain the

CAUTION

tanks before removing them in the fol-

In the following step, do not apply

lowing steps.

more vacuum than 25 in. (635 mm) Hg

or the fuel valve diaphragm will be

5. Drain the fuel tank as follows:

damaged.

NOTE

e. Gently operate the vacuum pump handle and

All models have a vacuum-operated

fuel valve installed. A hand-operated

apply up to a maximum of 25 in. (635 mm) Hg

vacuum pump is required to drain the

of vacuum. Once the vacuum is applied the

fuel tank.

fuel will start to flow into the gas can.

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FUEL, EXHAUST AND EMISSION SYSTEMS

295

FUEL TANK LINES AND

FITTINGS (ALL MODELS)

f. When fuel stops flowing through the hose,

turn the fuel valve off and release the vacuum.

Disconnect the vacuum pump and drain hose.

6. Disconnect the vent hose from the fuel tank.

8. Fuel hose (to

7. On FXDP models, perform the following:

1. Hose

carburetor)

a. Remove screws and washers securing the

2. Hose clamp

9. Hose clamp

3. Vapor valve

10. Filter

center console and remove the console.

4. Vent tube

11. Hex fitting

b. Disconnect all remaining electrical connec-

5. Hose insulator

12. Gasket

tors. Move the connectors and harness wires

6. Connector

13. Shutoff valve

out of the way.

7. Vacuum hose

14. Hose

c. Remove the screw and washer securing the

center console at the rear of the tank.

8. Disconnect the electrical connectors leading

from the gauges mounted on the fuel tank.

9. Disconnect the crossover hose from one side of

the fuel tank. Plug the tank opening and apply a

hemostat to the crossover hose (Figure 90).

10. Remove the nuts, washers and bolts (Figure

91) securing the fuel tank to the frame.

11. Lift off and remove the fuel tank.

NOTE

Store the fuel tank in a safe

place—away from open flames or

where it could be damaged.

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296

CHAPTER SEVEN

12. Drain any remaining fuel left in the tank into a

gas can.

13. Installation is the reverse of these steps while

noting the following:

a. Tighten the front and rear bolts and nuts to the

specification in Table 2.

b. Reconnect the fuel hose to the fuel valve and

secure it with a new hose clamp.

c. Refill the tank and check for leaks.

Inspection

1. Inspect all of the fuel and vent hoses for cracks,

deterioration or damage. Replace damaged hoses

with the same type and size materials. The fuel line

must be flexible and strong enough to withstand en-

gine heat and vibration.

2. Check the fuel line insulator for damage.

3. Check for damaged fuel tank mounting brackets.

Refer to Figure 92 and Figure 93, typical.

4. Remove the filler cap (Figure 94, typical) and

inspect the tank for rust or contamination. If there is

rust buildup inside the tank, clean and flush the tank

as described in this chapter.

5. Inspect the fuel tank for leaks.

FUEL SHUTOFF VALVE

A three-way vacuum-operated fuel shutoff valve

is mounted to the left side of the fuel tank. A re-

placeable fuel filter is mounted to the top of the fuel

shutoff valve (Figure 95).

To troubleshoot this valve, refer to Vacuum Oper-

ated Fuel Shutoff Valve Testing in Chapter Two.

Removal

WARNING

Gasoline is very volatile and presents

an extreme fire hazard. Be sure to

work in a well-ventilated area away

from any open flames (including pilot

lights on household appliances). Do

not allow anyone to smoke in the area

and have a fire extinguisher rated for

gasoline fires nearby.

1. Disconnect the negative battery cable from the

battery.

2. Turn the fuel shutoff valve to the OFF position.

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FUEL, EXHAUST AND EMISSION SYSTEMS

297

3. Drain the fuel tank as described under Fuel Tank

Removal/Installation in this chapter.

NOTE

The fuel shutoff valve can be removed

with the fuel tank in place. Figure 96

is shown with the fuel tank removed to

better illustrate the step.

4. Loosen the fuel valve fitting (A, Figure 96) and

remove the fuel shutoff valve (B) from the fuel tank.

Drain any residual gasoline that may still be in the

tank after the valve is removed.

VACUUM-OPERATED

Cleaning and Inspection

FUEL VALVE

1. Inspect the filter mounted on top of the fuel

valve. Remove and clean the filter of all contamina-

tion. Replace the filter if damaged.

2. Install a new filter gasket before installing the

filter onto the fuel valve.

3. Remove all sealant residue from the fuel tank

Fuel filter

and fuel valve threads.

Installation

Fitting

1. Install a new filter gasket onto the fuel shutoff

Handle

valve, then install the filter.

2. Coat the fuel valve threads with Loctite pipe

sealant.

3. Insert the fuel valve into the tank, then tighten

the hex fitting onto the fuel tank two turns.

Hose

4. Hold the hex fitting and tighten the fuel valve

(left-hand threads) two turns into the hex fitting.

5. Hold the fuel valve and tighten the hex fitting to

the specification in Table 2.

WARNING

If the hex fitting is turned more than

two turns on the valve, it may bottom

out on the valve and cause a fuel

leak. This could result in a dangerous

fire.

6. Install the insulator tube over the fuel hose.

7. Reconnect the fuel hose to the fuel shutoff valve

and secure it with a hose clamp.

8. Refill the fuel tank and check for leaks.

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298

CHAPTER SEVEN

FUEL TANK GAUGE

FUEL GAUGE ASSEMBLY

WARNING

(FXD, FXDS-CONV,

Because gasoline is extremely flam-

FXDX 1999-2000)

mable and explosive, perform this

procedure away from all open flames

(including appliance pilot lights) and

sparks. Do not smoke or allow some-

one who is smoking in the work area,

as an explosion and fire may occur.

Always work in a well-ventilated

area. Wipe up any spills immediately.

Removal/Installation

(FXD, FXDS-CONV, FXDX [1999-2000])

1. Screw

Refer to Figure 97.

2. Retainer

1. Remove the fuel tank as described in this chap-

3. Screw

ter.

4. Trim panel

5. Fuel gauge

2. Remove the gas filler cap.

6. Screw

3. Remove the five screws securing the fuel gauge

7. Bulb

retainer. Remove the retainer.

8. Trim panel ring

4. Use a flat-blade screwdriver and carefully pry

9. Sending unit

10. Gasket

the fuel gauge loose from the sending unit.

5. Withdraw the fuel gauge from the sending unit.

6. Remove the five screws and washers securing

the sending unit to the fuel tank.

FUEL GAUGE ASSEMBLY

CAUTION

(FXDL, FXDWG 1999-2000)

Do not bend the float arm during re-

moval of the sending unit. If bent, the

gauge will give inaccurate readings.

7. Carefully withdraw the sending unit while mov-

ing it back and forth, lifting and turning it in either

direction.

8. Remove the gasket from the fuel tank.

9. Install by reversing these removal steps while

noting the following:

a. Install a new gasket between the sending unit

and fuel tank.

b. Carefully install the sending unit to avoid

damage to the float arm.

c. Tighten all screws securely.

Removal/Installation

1. Screw

(FXDL, FXDWG [1999-2000])

2. Sending unit

3. Fuel gauge

4. Bulb

Refer to Figure 98.

5. Gasket

1. Remove the fuel tank as described in this chap-

6. Harness

ter.

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FUEL, EXHAUST AND EMISSION SYSTEMS

299

FUEL GAUGE ASSEMBLY (FXD, FXDX, FXDXT 2001)

1. Fuel gauge

2. Screw

3. Terminal socket

4. Retainer

5. Screw

6. Trim panel

7. Trim edging

8. Pin housing

9. Terminal socket

10. Trim panel ring

11. Screw

12. Socket housing

13. Terminal socket

14. Gasket

15. Sending unit

NOTE

6. Carefully withdraw the sending unit while mov-

The fuel gauge electrical wires are

ing it back and forth, lifting and turning it in either

routed through a tube in the fuel tank

direction.

and are secured with a clamp at the

7. Remove the gasket from the fuel tank.

bottom of the fuel tank. Loosen the

8. Install by reversing these removal steps while

clamp and make sure there is enough

slack in the wires to allow the gauge to

noting the following:

be pulled up and out of the fuel tank.

a. Install a new gasket between the fuel gauge

and fuel tank.

2. Pull straight up on the gauge and partially re-

b. Carefully install the sending unit to avoid

move it from the tank.

damage to the float arm.

3. Disconnect the electrical connector from the

c. Tighten all screws securely.

wires within the fuel tank. Do not disconnect the

electrical wires from the fuel gauge.

4. Remove the fuel gauge and the gasket.

Removal/Installation

5. Remove the five screws securing the sending

(FXD, FXDX, FXDXT [2001])

unit to the fuel tank.

Refer to Figure 99.

CAUTION

1. Remove the fuel tank as described in this chap-

Do not bend the float arm during re-

ter.

moval of the sending unit. If bent, the

gauge will give inaccurate readings.

2. Remove the gas filler cap (A, Figure 100).

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 15