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Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 28

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540

SUPPLEMENT

FUEL TANK-FUEL INJECTED MODELS (2004-ON)

1. Vent hose-

fuel tank-to-vapor

valve

2. Bolt

3. Filter cap

4. Gasket

5. Washer

6. Clip

7. Acorn nut

8. Fuel tank

9. Check valve and

fuel strainer

10. Fuel line

11. Acorn nut

12. Hose clamp

13. Crossover hose

14. Vent hose- vapor

valve-to-atmosphere

15. Clip

16. Vapor valve

11. Drain any remaining fuel left in the tank into a gas

FUEL TANK

can.

(2004-ON FUEL INJECTED MODELS)

12. Installation is the reverse of these steps. Note the

following:

WARNING

a. Tighten the front and rear bolts and nuts to

Some fuel may spill from the fuel tank

15-20 ft.-lbs. (20-27 N•m).

hose when performing this procedure.

Because gasoline is extremely flam-

b. Reconnect the fuel hose to the fuel valve and se-

mable and explosive, perform this

cure it with a new hose clamps.

procedure away from all open flames

(including appliance pilot lights) and

c. Connect the crossover hose and secure it with a

sparks. Do not smoke or allow anyone

new hose clamps.

to smoke in the work area, as an ex-

d. Refill the tank and check for leaks.

plosion and fire may occur. Always

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2002-2005 MODEL SERVICE INFORMATION

541

5. Disconnect the drain hose and reinstall the plug

into one end of it.

6. Repeat for the other side of the fuel tank.

7. Plug the fuel tank crossover fittings to prevent the

draining of fuel.

Removal/Installation

The crossover fuel hose is secured to the fuel tank

with non-reusable clamps. If the same type of clamps

are going to be reinstalled, purchase new ones before

servicing the fuel tank.

Refer to Figure 68.

1. Depressurize the fuel system as described under

Depressurizing The Fuel System in this Supplement.

2. Remove the seat as described in Chapter Thirteen.

NOTE

On models so equipped, always disarm

the optional TSSM security system

prior to disconnecting the battery or the

siren will sound.

3. Disconnect the battery negative cable as described

in Chapter Eight.

work in a well-ventilated area. Wipe

4. Remove the fuel tank console as described in this

up any spills immediately.

section.

WARNING

5. Disconnect the fuel pump electrical connector on

Make sure to route the fuel tank vapor

fuel tank top plate.

hoses so that they cannot contact any

hot engine or exhaust component.

WARNING

These hoses contain flammable vapors.

A small amount of fuel will drain out of

If a hose melts from contacting a hot

the fuel tank when the fuel line is dis-

part, leaking vapors may ignite, caus-

connected from the base of the tank.

ing a fire.

Place several shop cloths under the fuel

line fitting to catch any spilled fuel prior

to disconnecting it. Discard the shop

Fuel Tank Draining

cloths in a suitable safe manner.

1. Depressurize the fuel system as described under

6. Pull up the chrome sleeve on the fuel line quick

Depressurizing The Fuel System in this section.

disconnect fitting (Figure 69) and disconnect the fuel

2. Make a drain hose from 5/16 in. inner diameter

supply line from the fuel tank.

hose and plug one end of it. Make it long enough to go

7. Disconnect the crossover hose (Figure 70) from

from the fuel tank crossover hose fitting to a gas can.

one of the fittings on the fuel tank. Drain the fuel tank

3. Disconnect the crossover hose from one of the fit-

as in this section.

tings on the fuel tank. Immediately connect the drain

8. Disconnect the vent hose from the fuel tank.

hose made in Step 2 to the fuel tank fitting.

4. Place the plugged end of the drain hose into the gas

9. Remove the front and rear bolts, washers and acorn

can and remove the plug. Drain the fuel from that side

nuts securing the fuel tank to the frame.

of the fuel tank.

10. Lift off and remove the fuel tank.

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542

SUPPLEMENT

NOTE

an inaccurate reading and must be re-

Store the fuel tank in a safe place away

placed.

from open flames or where it could be

damaged.

11. Carefully remove the top plate and sending unit

while moving it back and forth and while lifting and

11. Drain any remaining fuel left in the tank into a gas

turning it in either direction.

can.

12. Remove the gasket from the fuel tank and discard

12. Installation is the reverse of these steps. Note the

it.

following:

13. To remove the fuel level sender from the top

a. Tighten the front and rear bolts and nuts to

plate, move the locking tab toward the rear of the top

15-20 ft.-lbs. (20-27 N•m).

plate and disengage the sender from the top plate. Re-

b. Reconnect the fuel line quick disconnect fitting

move the sender from the top plate.

(Figure 69) onto the fuel tank until it clicks into

14. Install by reversing these removal steps. Note the

the locked position. Pull down on the fuel line

following:

to make sure it is secured to the fitting.

a. Install a new gasket between the top plate and

c. Refill the tank and check for leaks.

the fuel tank. Do not apply any type of sealant

to the gasket.

FUEL TANK TOP PLATE AND

b. Use new T20 Torx screws and tighten in a

FUEL GAUGE SENDING UNIT

crisscross pattern to 20 in.-lb. (2.3 N•m).

(2004-ON ALL MODELS)

c. Refill the tank and check for leaks.

Refer to Figure 71.

1. On fuel injected models, depressurize the fuel sys-

FUEL PUMP AND FUEL FILTER

tem as described in this chapter section.

(2004-ON FUEL INJECTED MODELS)

2. Remove the seat as described in Chapter Thirteen.

3. Drain the fuel tank as described in this

Refer to Figure 72.

Supplement.

4. Remove the fuel tank console as described in this

section.

Fuel Pump and Fuel Filter

5. On models so equipped, remove the fuel level

Removal/Installation

gauge as described in this section.

6A. On carbureted models, disconnect the electrical

1. Remove the top plate assembly as previously de-

connector from the top plate of the fuel level sender

scribed in this section.

unit.

2. Depress the tab and disconnect the fuel hose from

6B. On fuel injected models, disconnect the electrical

the fuel pump assembly.

connector from the top plate of the fuel pump/sender.

3. Disconnect the electrical connector from the fuel

7. Disconnect the fuel tank vent hose from the top plate.

pump assembly.

8. Remove the T20 Torx screws securing the top

4. Lift up on the fuel pump assembly tab, push the as-

plate to the fuel tank. Discard the screws as they can-

sembly toward the front of the fuel tank and disengage

not be reused.

it from the fuel tank.

9. Rotate the top plate toward the right side until the

5. Rotate the fuel pump assembly clockwise and up-

vent tube clears the fuel tank opening.

ward. Carefully remove the assembly from the left

10. On fuel injected models, perform he following:

side of the fuel tank opening.

a. Depress the tab and remove the fuel

6. Install by reversing these removal steps. Note the

pump/sender wiring from the top plate.

following:

b. Disconnect the wire harness from the fuel

a. Install a new O-ring on the fuel hose where it

pump.

connects to the fuel pump assembly.

CAUTION

b. Push the fuel hose onto the assembly until it

Do not bend the arm during removal of

clicks into the locked position. Pull on the fuel

the sending unit. If bent, it will result in

hose to make sure it is secured to the fitting.

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2002-2005 MODEL SERVICE INFORMATION

543

FUEL TANK TOP PLATE-ALL MODELS (2004-ON)

1. Screw

2. Wiring harness

3. Filler cap

4. Gasket

5. Top plate (FXD, FXDI, FXDX,

FXDXI, FXDC, FXDCI)

6. Fuel restrictor

7. Gasket

8. Connector

9. Fuel level sending unit

10. Top plate (FXDWG, FXDWGI)

11. Gasket

12. Top plate (FXDL, FXDLI)

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544

SUPPLEMENT

FUEL PUMP AND FILTER-FUEL INJECTED MODELS

(2004-ON)

1. Connector

2. Wiring harness

3. Regulator

4. O-ring

5. Regulator ring

6. Upper retainer

7. Fuel filter

8. O-ring

9. Filter housing

10. Fuel level sending unit

11. Wiring harness

12. Upper insulator

13. Fuel pump

14. Lower insulator

15. Lower retainer

16. Inlet strainer

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2002-2005 MODEL SERVICE INFORMATION

545

Fuel Filter Replacement

2. Depress the tabs on the fuel inlet strainer and re-

move the strainer from the fuel pump and the lower re-

1. Remove the fuel pump and fuel filter assembly as

tainer.

previously described.

3. Install a new inlet strainer onto the fuel pump inlet

2. Depress the tabs on fuel filter housing and separate

receptacle and onto the lower retainer.

the end cap from the fuel filter housing.

4. Push the inlet strainer onto the lower retainer until

3. Remove the O-ring securing the fuel filter to the

the tabs click into the locked position.

housing. Remove the filter and discard it.

5. Install the fuel pump and fuel filter assembly as

4. Install a new filter into the housing and secure it

previously described.

with a new O-ring.

5. Attach the fuel filter housing onto the end cap and

Fuel Pump Replacement

push in on until the tabs click into the locked position.

6. Install the fuel pump and fuel filter assembly as

1. Remove the fuel pump and fuel filter assembly as

previously described.

2. Use a flat blade screwdriver and break the fuel

pump locking tabs securing the fuel hose to the end

Fuel Regulator Replacement

cap.

3. Remove the fuel inlet strainer as previously de-

1. Remove the fuel pump and fuel filter assembly as

scribed.

previously described.

4. Disconnect the electrical connector from the fuel

2. Remove the wire terminal from the end of the reg-

pump.

ulator and filter housing.

5. Depress the locking tabs and separate the lower re-

3. Disengage the clip and remove it from the regula-

tainer from the upper retainer.

tor.

6. Remove the fuel pump from the upper retainer.

4. Withdraw the regulator and O-ring from the filter

7. If necessary, replace the isolators into the upper

housing. Discard the O-ring.

and lower retainers.

5. Install a new O-ring and regulator into the filter

8. Install a new fuel pump into the upper retainer.

housing. Push in until both parts are seated.

9. Install the lower retainer onto the upper retainer

6. Install the clip and push in on until the tabs click

and push in on until the tabs click into the locked posi-

into the locked position.

tion.

7. Install the fuel pump and fuel filter assembly as

10. Install the hose onto the end cap.

previously described.

11. Connect the electrical connector onto the fuel

pump.

Fuel Inlet Strainer Replacement

12. Install the fuel inlet strainer as previously de-

scribed.

1. Remove the fuel pump and fuel filter assembly as

13. Install the fuel pump and fuel filter assembly as

previously described.

Table 10 FUEL SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Fuel cap trim ring screw

18-22

2.0-2.5

Fuel gauge bolts

15-20

20-27

Fuel tank console screw

18-24

2.0-2.7

Fuel tank mounting bolts

15-20

20-27

Fuel tank top plate screws

2.3

Induction module bolts (EFI)

upper and lower

97-142

11-16

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546

SUPPLEMENT

CHAPTER EIGHT

ELECTRICAL SYSTEM

ALTERNATOR

wiring harness grommet to help ease it

out of the crankcase boss receptacle.

Refer to Figure 73.

7. Use an awl to carefully lift the capped lip on the

grommet (Figure 75) from the crankcase and push it

Rotor Removal/Installation

into the bore.

8. Carefully push the stator wires and grommet (B,

The removal and installation procedure is the same

Figure 74) through the crankcase bore and remove

as on all other models, except the washer previously

the stator assembly.

used inside and outside of the rotor has been

9. Inspect the stator mounting surface on the crank-

eliminated.

case for oil residue from a damaged oil seal. Clean it

off if necessary.

10. Inspect the stator wires (A, Figure 76, typical) for

Stator Removal

fraying or damage.

1. Remove the rotor as described in this Supplement

11. Inspect the rubber grommet (B, Figure 76) for

and Chapter Eight.

deterioration or hardness.

12. Check the stator connector pins for looseness or

NOTE

damage.

On models so equipped, always disarm

the optional TSSM security system

prior to disconnecting the battery or the

Stator Installation

siren will sound.

1. Apply a light coat of electrical contact cleaner or

2. Disconnect the negative battery cable as described

glass cleaner to the wiring harness grommet to help

in this Supplement.

ease it into the crankcase boss receptacle.

3. Pull back the rubber boot at the plug cover. Release

2. Insert the electrical harness and grommet into the

the locking tab and disconnect the alternator rotor

crankcase boss receptacle and carefully pull it through

electrical connector from the voltage regulator

until the grommet is correctly seated.

connector.

CAUTION

4. Insert a small screwdriver between the socket

New T27 Torx screws must be installed.

housing side of connector going to the alternator stator

The threadlocking compound origi-

and the locking wedge on the socket housing. Gently

nally applied to the Torx screws is for

pivot the screwdriver tip and pop the wedge loose.

one time use only. If a used Torx screw

5. Lift the terminal latches inside the socket housing

is installed, it can work loose and cause

and back the sockets through wire end of connector.

engine damage.

6. Remove the four T27 Torx screws (A, Figure 74)

3. Move the stator into position on the crankcase and

securing the stator assembly to the crankcase. New

install four new Torx screws (A, Figure 74). Tighten

Torx screws must be used on installation.

the screws to 55-75 in.-lb. (6.2-8.4 N•m).

NOTE

4. Move the wires to the right side of the motorcycle.

If necessary, spray electrical contact

5. Apply a light coat of dielectric compound to the

cleaner or glass cleaner around the

electrical connector prior to assembling it. Reassem-

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2002-2005 MODEL SERVICE INFORMATION

547

CHARGING SYSTEM-ALL MODELS (2004-ON)

From main harness

1. Rotor

8. Connector

2. Stator coil assembly

9. Washer

3. Allen bolt

10. Screw

4. Voltage regulator

11. Nut

5. Bolt

12. Connector

6. Connector

13. Connector

7. Plug cover

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548

SUPPLEMENT

ble the electrical connector socket by reversing Steps

4 and 5 of Removal. Make sure it has locked together

securely.

6. Connect the alternator rotor electrical connector

onto the voltage regulator connector. Make sure they

are push together until the tab clicks into the locked

position. Pull the rubber boot back into place.

7. Install the rotor as described in this Supplement.

VOLTAGE REGULATOR

Removal/Installation

NOTE

Refer to Figure 73.

On models so equipped, always disarm

the optional TSSM security system

NOTE

prior to disconnecting the battery or the

On models so equipped, always disarm

siren will sound.

the optional TSSM security system

prior to disconnecting the battery or the

1. Disconnect the negative battery cable as described

siren will sound.

in Chapter Eight.

1. Disconnect the negative battery cable as described

2. Remove the cover from the electrical panel as

in Chapter Eight.

described in this Supplement.

2. Pull back the rubber boot at the plug cover. Release

3. Disconnect the secondary lead from each spark

the locking tab and disconnect the voltage regulator

plug (Figure 78).

electrical connector from the alternator stator

4. Disconnect the front cylinder’s secondary lead

connector.

from the clip on the frame.

3. Release the locking tab and disconnect the voltage

5. Disconnect the electrical connector from the

regulator electrical connector from the main wiring

backside of the ignition coil.

harness.

4. Remove the two bolts securing the voltage regula-

6A. On FXDL, FXDLI, FXDWG, FXDWGI,

tor to the frame cross member.

FXDC and FXDCI models, unscrew the long screw

5. Remove the voltage regulator and related wiring

and washer securing the ignition coil cover and ig-

from the frame.

nition coil. Do not lose the spacer between the cover

and the ignition coil.

6. Install by reversing these removal steps. Note the

following:

6B. On FXD, FXDI, FXDX and FXDXI models,

a. Tighten the bolts to 60-80 in.-lb. (6.8-9.0 N•m).

unscrew the short screw securing the ignition coil.

b. Apply a light coat of dielectric compound to the

7. Remove the ignition coil from the electrical

electrical connectors prior to installing them.

panel.

c. Connect both voltage regulator electrical con-

8. Install by reversing these removal steps. Tighten

nectors. Make sure they are push together until

the screws to 50 in.-lb. (5.6 N•m).

the tab clicks into the locked position. Pull the

rubber boot back into place.

Ignition Control Module (2004-On

Carbureted Models) and Electronic

IGNITION SYSTEM

Control Module (2004-On Fuel

(2004-ON MODELS)

Injected Models) Removal/Installation

Ignition Coil Removal/Installation

Refer to the Electrical Panel section in this

Refer to Figure 77.

Supplment.

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2002-2005 MODEL SERVICE INFORMATION

549

IGNITION SYSTEM COMPONENTS-ALL MODELS

(2004-ON)

1. Ignition coil (fuel injected models)

2. Screw (FXD, FXDI, FXDX, FXDXI)

3. Spacer (FXDL, FXDLI, FXDWG, FXDWGI)

4. Coil cover (fuel injected models)

5. Washer

6. Screw (FXDL, FXDLI, FXDWG, FXDWGI)

7. Ignition coil (carbureted models)

8. Coil cover (carbureted models)

9. Ignition module (carbureted models)

10. Ignition module (fuel injected models)

11. Spark plug cable-front cylinder

12. Spark plug cable-rear cylinder

13. Spark plugs

14. Screw

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550

SUPPLEMENT

Crankshaft Position Sensor (CKP)

(2004-On Models)

The crankshaft position sensor (Figure 79) is lo-

cated on the front left side of the crankcase next to

the oil filter.

NOTE

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

3. Push in on the bulb (B, Figure 81), rotate it and re-

in Chapter Eight.

move it.

2. Remove the Allen screws, and captive washers,

4. Install a new bulb and lens.

and withdraw the CKP sensor (Figure 80) and

5. Push the lens cap into the housing until is snaps

O-ring from the crankcase.

into place.

3. Located above the voltage regulator and alterna-

tor stator electrical connector (Figure 73), push on

the CKP electrical connector and disengage it from

Taillight/Brake Light Replacement

the T-stud on the mounting plate.

(2003-On Models)

4. Separate the electrical connector and remove the

CKP and wiring harness from the frame.

Taillight/Brake light bulb replacement is the

5. Install by reversing these removal steps. Note

same as previous models with the following excep-

the following:

tion. On 2003 models, rotate the blown bulb and re-

a. Install a new O-ring and apply engine oil to it

move it from the socket assembly, then install a new

prior to installation.

bulb. On 2004-on models, pull the bulb straight out

b. Tighten the Allen screws to 90-120 in.-lb.

from the socket assembly, and install a new bulb.

(10.2-13.6 N•m).

The following are the bulb specifications:

1. Taillight bulb: 7 watts.

2. Brake light bulb: 2003 models (bayonet type) 27

STARTING SYSTEM

watts, 2004-on models (wedge type) 25 watts.

Starter Removal/Installation

(2004-On Models)

SWITCHES

The starter removal and installation is the same as

Ignition/Light Switch

on previous models with the exception of the torque

Removal/Installation

specification on the starter jackshaft bolt. Tighten

(2004-On FXDWG and FXDWGI Models)

the bolt to 60-80 in.-lb. (6.8-9.0 N•m).

1. Remove the fuel tank console for FXDWG and

FXDWGI models as described in the Chapter Seven

LIGHTING SYSTEM

section of this Supplement.

2. Note the location and color of the wire colors at-

Front Turn Signal Bulb Replacement

tached to the ignition switch. Disconnect the wires

(2003-On Models)

from the ignition switch.

1. Locate the notch in the lens cap.

3. Remove the screws securing the ignition switch to

2. Insert a coin into the notch and carefully twist the

the underside of the console and remove the switch.

coin until the lens cap come off the housing (A, Fig-

4. Install by reversing these removal steps. Tighten

ure 81).

the mounting screws securely.

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2002-2005 MODEL SERVICE INFORMATION

551

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

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552

SUPPLEMENT

ELECTRICAL PANEL (2004-ON)

1. Screw

8. Cover

2. Washer

9. Main fuse (40A)

3. Siren

10. Washer

4. Electrical panel

11. Bolt

5. Grommet

12. Turn signal module (TSM)

6. Mounting pin

or turn signal module

7. Nut

(TSSM)

ELECTRICAL PANEL

(2004-ON MODELS)

The electrical panel assembly mounts on the left

side of the motorcycle. The panel assembly houses the

fuses, ignition control module (carbureted models)

or electronic control module (fuel injected models),

starter relay (carbureted models), system relay (fuel

injected models), turn signal canceller, turn sig-

nal/security module and siren.

Refer to Figure 82.

prior to disconnecting the battery or the

siren will sound.

Removal/Installation

1. Remove the seat as described in Chapter Thirteen.

NOTE

On models so equipped, always disarm

2. Disconnect the negative battery cable as described

the optional TSSM security system

in Chapter Eight.

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2002-2005 MODEL SERVICE INFORMATION

553

3. Hold onto both sides of the cover, pull straight out

module (ECM [2004-on fuel injected models]), per-

and remove the cover (Figure 83) from the electrical

form the following:

panel.

a. Carefully disconnect the

12-pin

(ICM) or

4. Remove the 40 amp main fuse from the connector.

36-pin (ECM) electrical connector (B, Figure

5. Disconnect the main fuse connector as follows:

85) from the module.

a. Insert a small flat blade screwdriver into the

b. Disconnect the ignition coil four-pin electrical

slots on each side of the main fuse holder.

connector from the backside of the ignition coil

b. Carefully depress the tabs on the main fuse

unit.

holder connector and disengage it from the

c. Disconnect the spark plug secondary wires

electrical panel.

from the ignition coil unit.

6. To remove the TSM/TSSM unit, perform the fol-

lowing:

d. Remove the front long screws and washers se-

a. Depress the tab (A, Figure 84) on the electrical

curing the electrical panel to the frame mount.

panel securing the TSM/TSSM unit (B).

e. Remove the top short screws and washers se-

b. Pull the TSM/TSSM unit from the opening in

curing the frame mount.

the panel, disconnect the electrical connector

f. Carefully push the electrical connectors back

from unit, and remove it.

through the opening in the electrical panel.

7. Slide the data link connector (A, Figure 85) to-

ward the front and disengage it from the electrical

NOTE

panel.

On fuel injected models, note the loca-

8. To remove the ignition control module (ICM

tion of the ground strap on the front

[2004-on carbureted models]) or electronic control

mounting screw.

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554

SUPPLEMENT

g. Remove the screws securing the ICM or ECM

TURN SIGNAL MODULE (TSM) AND

unit to the base of the electrical panel and re-

TURN SIGNAL MODULE/SECURITY

move the unit.

MODULE (TSSM)

(2004-ON MODELS)

9. Remove the electrical panel from the frame.

10. Install by reversing these removal steps. Note the

The turn signal module and turn signal module/se-

following:

curity module operation is the same as on prior years

with the exception of the removal and installation of

a. Tighten the top short screws to 100 in.-lb. (11.3

the unit.

N•m).

Removal and installation are covered under Electri-

b. Tighten the front long screws to 50 in.-lb. (5.6

cal Panel in this section.

N•m).

c. Apply a light coat of dielectric compound to the

STARTER RELAY REPLACEMENT

electrical connectors prior to installing them.

(2004-ON MODELS)

d. Connect the electrical connectors. On connec-

tors so equipped, make sure they are push to-

NOTE

gether until the tab clicks into the locked

On models so equipped, always disarm

position.

the optional TSSM security system

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555

FUSE PANEL (CARBURETED MODELS)

1. Main 40A fuse

2. Spare fuse

3. Spare fuse

4. Battery 15A fuse

5. Accessory 15A fuse

6. Instrument 15A fuse

7. Ignition 15A fuse

8. Lights 15A fuse

9. Starter 15A relay

prior to disconnecting the battery or the

SYSTEM RELAY REPLACEMENT

siren will sound.

(2004-ON FUEL INJECTED MODELS)

NOTE

1. Remove the seat as described in Chapter Thirteen.

On models so equipped, always disarm

the optional TSSM security system

2. Disconnect the negative battery cable as described

prior to disconnecting the battery or the

in Chapter Eight.

siren will sound.

3. Hold onto both sides of the cover, pull straight out

1. Remove the seat as described in Chapter Thirteen.

and remove the cover (Figure 83) from the electrical

2. Disconnect the negative battery cable as described

panel.

in Chapter Eight.

4. Pull straight out and remove the starter relay from

3. Hold onto both sides of the cover, pull straight out

the electrical panel. Refer to Figure 86 or Figure 87.

and remove the cover (Figure 83) from the electrical

panel.

5. Install the starter relay onto the electrical panel.

4. Pull straight out and remove the system relay from

6. Install the cover onto the electrical panel.

the electrical panel. Refer to Figure 87.

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556

SUPPLEMENT

FUSE PANEL (FUEL INJECTED MODELS)

1. Main 40A fuse

2. ECM 15A fuse

3. Fuel pump 15A fuse

4. Spare fuse

5. Spare fuse

6. Battery 15A fuse

7. Accessory 15A fuse

8. Instrument 15A fuse

9. Ignition 15A fuse

10. Lights 15A fuse

11. Starter relay

12. System relay

5. Install the starter relay onto the electrical panel.

1. Remove the fuel tank console as described in the

6. Install the cover onto the electrical panel.

Chapter Seven section of this chapter.

2. Unscrew and remove the reset switch rubber boot.

3. Remove the reset switch from the console.

INSTRUMENTS

4. Remove the screws securing the back clamp to the

Removal/Installation

console.

(2005 FXDC, FXDCI Models)

5. Remove the back clamp and remove the speedom-

eter and/or tachometer from the console.

Removal and installation is the same as on prior

6. Remove the gasket from the meter or console.

FXD Series models with the exception of the shape of

7. Install by reversing these removal steps. Note the

the shape of the meter housing as shown in Figure 88.

following:

a. If necessary, apply alcohol or glass cleaner to

the gasket to ease its installation onto the meter.

Removal/Installation

b. Tighten the back clamp screws securely. Do not

(2004-On FXDL, FXDLI Models)

pinch the wiring between the back clamp and

Refer to Figure 89.

the console.

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2002-2005 MODEL SERVICE INFORMATION

557

INSTRUMENTS-FXDC, FXDCI (2005)

1. Reset switch

10. Back plate

2. Reset switch rubber boot

11. Screw

3. Speedometer

12. Connector (12-pin)

4. Connector

13. Indicator lamp bezel

5. Front gasket

14. Indicator lamp lens

6. Bolt

15. Indicator lamp housing

7. Washer

16. Screw

8. Handlebar holder/speedometer

17. Lamps

mounting bracket

18. Wiring harness/bulb sockets

9. Rear gasket

Removal/Installation

a. If necessary, apply alcohol or glass cleaner to

(2004-On FXDWG, FXDWGI Models)

the gasket to ease its installation onto the meter.

b. Tighten the back clamp screws securely. Do not

Refer to Figure 90.

pinch the wiring between the back clamp and

1. Remove the fuel tank console as described in the

the console.

Chapter Seven section of this Supplement.

2. Unscrew and remove the reset switch rubber boot.

3. Remove the reset switch from the console.

FUSES AND MAXI-FUSE

4. Use a flat blade screwdriver and carefully pry be-

(2004-ON MODELS)

tween the three tabs on the back clamp and release it

from the speedometer. Remove the back clamp.

All models are equipped with a series fused to pro-

5. Remove the speedometer and gasket from the con-

tect the electrical system. The number of fuses varies

sole.

depending on model. The 40 amp circuit breaker used

6. Install by reversing these removal steps. Note the

on prior models has been replaced with the 40 amp

following:

maxi-fuse. Always carry spare fuses

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558

SUPPLEMENT

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

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2002-2005 MODEL SERVICE INFORMATION

559

FUEL TANK CONSOLE

(FXDWG, FXDWGI)

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

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