Content      ..     25      26      27      28     ..

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

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

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

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

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

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

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.

Content      ..     25      26      27      28     ..