Harley Davidson Touring 2004 Service Manual sm09b

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INDUCTION MODULE ASSEMBLY 9.5

GENERAL

See Figure 9-23. The Induction Module Assembly consists of
the following components:

●

Induction Module
Fuel Supply Line

●

Fuel Rail/Fuel Supply Tube

●

●

Fuel Injectors

●

Intake Air Temperature Sensor
Throttle Position Sensor

●

Manifold Absolute Pressure Sensor

●

●

Idle Air Control

INDUCTION MODULE

REMOVAL

1. Partially remove fuel tank. See Section 9.4 FUEL TANK

(FUEL INJECTED), PA RTIAL REMOVAL, either FLHT/
C/U/I, FLTRI or FLHR/C/S/I.

1. Fuel Injector (Front)

2. Throttle Cable Bracket

3. Idle Air Control

4. Throttle Position Sensor

5. Purge Tube Fitting
(California Models Only)

6. Intake Air Temperature Sensor

7. Manifold Absolute Pressure
Sensor

8. Fuel Injector (Rear)

9. Fuel Rail

10. Fuel Supply Tube

10

1

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

CLEANER, REMOVAL.

3. Pull purge tube from fitting at top of induction module
(California models only). See Figure 9-23.

4. Using a needle nose pliers, carefully pull idle cable bar­rel from upper hole in throttle wheel. Pull throttle cable
barrel from lower hole. Using slots, release idle and
throttle cables from guides in throttle cable bracket.

5. On cruise control equipped models, remove E-clip from
sleeve at end of cruise cable housing. Using slot,
remove cable housing from cable guide in throttle cable
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. See Fig-

ure 9-24.

6. Remove idle air control and manifold absolute pressure
sensor connectors. Pull external latch(es) outward and
use rocking motion to separate pin and socket halves.

7. Depress wire form to remove electrical connectors from
front and rear fuel injectors.

8. Remove throttle position sensor and intake air tempera­ture sensor connectors.

Front

2

3

f2162x9x

9

7

8

Figure 9-23. Induction Module Assembly

Rear

6

5

4

2004 Touring: Fuel Injection 9-27

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f1965x8x

Wheel Pin

End Fitting

Figure 9-24. Remove End Fitting From Wheel Pin

Button

f1922x9x

Figure 9-25. Remove Fuel Supply Line From Supply Tube

9. Remove right side allen head socket screws from front
and rear cylinder head flange adapters. For best results,
use a long 1/4 inch ball allen head socket with end driver
4 inches long.

10. Moving to opposite side of vehicle, just loosen left side
allen head socket screws from flange adapters. Slots in
flanges make removal of left side screws unnecessary.
To better access bolts, loosen acorn nut and swing horn
assembly out of the way.

11. Slide induction module out from right side of vehicle.
Use caution around horn bracket to prevent damage to
fuel line.

1WARNING1WARNING

A small amount of gasoline will drain from the fuel sup­ply line when disconnected from the supply tube. Thor­oughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flamma­ble and highly explosive. Inadequate safety precautions
could result in death or serious injury.

12. Depress button on inboard side of fuel supply line and

remove from supply tube. See Figure 9-25.

13. Remove seals from flange adapters. Discard seals.
Remove flange adapters from outlet ports of induction
module.

14. If it should become necessary to split the induction mod­ule, that is, separate the throttle body from the intake
manifold, proceed as follows:

a. Remove top and bottom T20 TORX screws to sepa-

rate intake manifold and throttle body flanges.

b. Remove O-ring from counterbore of throttle body

flange. Discard O-ring.

INSTALLATION

1. If induction module was split, assemble the intake mani­fold and throttle body as follows:

a. Apply a thin coat of clean engine oil to

Install O-ring in counterbore of throttle body flange.
Mate intake manifold and throttle body flanges.

b. Apply Loctite Wicking Threadlocker 290 (green) to

threads of two T20 TORX screws. Install screws and
alternately tighten to 27-33
Allow approximately 3-6 hours to elapse for com­pound to cure.

2. Slide fuel supply line onto tube at top of induction mod­ule. A slight tug will verify that the line is locked in place.

3. Orientate the induction module as shown in Figure 9-23.
With the counterbore facing outward, slide cylinder head
flange adapters onto outlet ports of induction module.
The flange adapters are not interchangeable. Look next
to the slotted bolt hole for a stamp that indicates F(ront)
and R(ear) cylinder.

4. Place a
eled side in against the counterbore.

5. Standing on right side of engine, slide induction module
toward installed position so that open-ended slots on
flange adapters begin to engage allen head socket
screws loosely installed on left side. Use caution around
horn bracket to prevent damage to fuel line.

6. Install sleeve on throttle cable housing into shorter cable
guide at top of throttle cable bracket. Drawing throttle
cable downward, fit barrel end into lower hole in throttle
wheel. Install sleeve and spring on idle cable housing
into longer cable guide at bottom of throttle cable bracket
inserting barrel end into upper hole in throttle wheel.

7. On cruise control equipped models, slide groove in
cruise cable end fitting over cap of wheel pin. Push on
end fitting until it snaps in place. Using slot, slip cruise
cable housing into cable guide in throttle cable bracket.
Install
ing.

8. Align fixed holes in flange adapters with those in cylinder
heads and start allen head socket screws. For best
results, use a long 1/4 inch ball allen head socket with
end driver 4 inches long.

new

seal in each flange adapter with the bev-

new

E-clip on sleeve at end of cruise cable hous-

in-lbs

new

O-ring.

(3.1-3.7 Nm).

9-28 2004 Touring: Fuel Injection

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1WARNING1WARNING

1WARNING1WARNING

f1966x9x

T27 TORX

f2079x9x

Screws

Breather Bolts

Backplate

11. Remove breather bolts and T27 TORX screws to remove
backplate, if installed.

12. Tighten allen head socket screws in fixed holes of flange
adapters to 96-144

13. Remove breather bolts to remove alignment bracket, if
installed.

14. Install electrical connectors on fuel injectors.

15. Install manifold absolute pressure sensor and idle air
control connectors.

16. Install intake air temperature sensor and throttle position
sensor connectors.

17. Connect purge tube to fitting at top of induction module
(California models only). See Figure 9-23.

18. Install fuel tank. See Section 9.4 FUEL TANK (FUEL

INJECTED), INSTALLATION (AFTER PARTIAL
REMOVAL), FLHT/C/U/I, FLTRI or FLHR/C/S/I.

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

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

CLEANER, INSTALLATION.

21. Check throttle and idle control cable adjustment. Check
cruise cable adjustment.

in-lbs

(10.9-16.3 Nm).

Bracket

Figure 9-26. Install Backplate or Bracket

9. Use the air cleaner backplate or INDUCTION SYSTEM
ALIGNMENT BRACKET (P&A Part No. 40054-01) to
properly locate induction module. Proceed as follows:

a.

Backplate

plate to front and rear cylinder heads. Install three
T27 TORX screws to secure backplate to face of
induction module. See upper frame of Figure 9-26.

b.

Alignment bracket

into holes in face of induction module, install two
breather bolts to fasten bracket to front and rear cyl­inder heads. See lower frame of Figure 9-26.

10. Tighten allen head socket screw in fixed holes of flange
adapters until snug. Moving to left side of engine, tighten
screws in slotted holes to 96-144
If moved, swing horn assembly back into position and
tighten acorn nut.

: Install two breather bolts to fasten back-

: Fitting pins on inboard side

in-lbs

(10.9-16.3 Nm).

FUEL SUPPLY LINE

The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
supply line is disconnected. Inadequate safety precau­tions could result in death or serious injury.

REMOVAL

1. Partially remove fuel tank. See Section 9.4 FUEL TANK

(FUEL INJECTED), PARTIAL REMOVAL, FLHT/C/U/I,
FLTRI or FLHR/C/S/I.

A small amount of gasoline will drain from the fuel sup­ply line when disconnected from the fuel tank. Thor­oughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flamma­ble and highly explosive. Inadequate safety precautions
could result in death or serious injury.

NOTE

Check valve in the fuel tank fitting impedes any further fuel
seepage once external fuel line has drained.

2004 Touring: Fuel Injection 9-29