Harley Davidson Touring 2004 Service Manual sm09a
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SPECIFICATIONS 9.1
EFI FUSES
Fuel Pump 15 Blue Blade
ECM Power 15 Blue Blade
Spare
Fuel Pump
ECM Power
EFI System
Relay
Figure 9-1. EFI Fuses (Under Right Side Cover)
f2223x9x
TORQUE VALUES
Item
Battery hold-down clamp
TORX bolt
Battery cable bolt 60-96
ECM socket screws 50-60
Electrical bracket flange
nuts
Crank position
sensor screw
Engine sensor harness
clip screws to crankcase
Engine temperature
sensor
Fuel tank rear mounting
bolt
Fuel tank front mounting
bolts
Fuel tank canopy TORX
screws
Fuel level sender TORX
screw
Fuel supply line
quick-connect fitting
Fairing lower U-bolt
retainer locknuts
Fairing lower cap screws
Intake manifold to throttle
body TORX screws
Intake flange adapter
screws
Exhaust flange adapter
screws
Fuel rail TORX screws
Fuel supply tube clamp
TORX screw
Intake air temperature
sensor TORX screws
Throttle position sensor
TORX screws
Throttle cable bracket
side TORX screw
Idle air control flange
screws
Console mounting bolt
acorn nut
ft/in-lbs Nm
15-20 ft-lbs
in-lbs
in-lbs
36-48
in-lbs
90-120
in-lbs
25-35
in-lbs
120-180
in-lbs
15-20 ft-lbs 20-27 Nm
15-20 ft-lbs 20-27 Nm
18-24
in-lbs
25-35
in-lbs
22-26 ft-lbs 29.8-35.3 Nm
35-40
in-lbs
10-15
in-lbs
27-33
in-lbs
96-144
in-lbs
60-80
in-lbs
27-33
in-lbs
27-33
in-lbs
12
in-lbs
27-33
in-lbs
27-33
in-lbs
25
in-lbs
50-90
in-lbs
20-27 Nm
6.8-10.9 Nm
5.7-6.8 Nm
4.1-5.4 Nm
10.2-13.6 Nm
2.8-4.0 Nm
13.6-20.3 Nm
2.0-2.7 Nm
2.8-4.0 Nm
4.0-4.5 Nm
1.1-1.7 Nm
3.1-3.7 Nm
10.9-16.3 Nm
6.8-9.0 Nm
3.0-3.7 Nm
3.0-3.7 Nm
1.4 Nm
3.0-3.7 Nm
3.0-3.7 Nm
2.8 Nm
5.7-10.2 Nm
2004 Touring: Fuel Injection 9-1
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NOTES
9-2 2004 Touring: Fuel Injection
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ELECTRICAL BRACKET ASSEMBLY 9.2
GENERAL
See Figure 9-2. The electrical bracket assembly is mounted
beneath the side cover on the right side of the vehicle. The
electrical bracket assembly carries the following components:
●
Data Link Connector
●
Main Harness to EFI Harness Connector
●
ECM Power Fuse/Fuel Pump Fuse
●
EFI System Relay
●
Electronic Control Module (ECM)
●
Vehicle Speed Sensor Connector
Optional Security Siren Connector
●
DATA LINK CONNECTOR
SETTING ENGINE IDLE SPEED
NOTE
Engine idle speed can only be set using DIGITAL TECHNICIAN (Part No. HD-44750). Do not tamper with the throttle
stop screw as it will not permanently change idle speed.
1. Turn the ignition/light key switch to OFF.
2. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
3. Gently pull side cover from frame downtubes (no tools
required).
1
2
6,7
5
4
1. Data Link Connector [91]
2. Main Harness Connector [8]
3. Fuse Block (ECM Power Fuse, Fuel Pump
Fuse, EFI System Relay)
4. Electronic Control Module Connector [78]
Figure 9-2. Electrical Bracket Assembly
3
f1917x9x
5. Electronic Control Module (ECM)
6. Vehicle Speed Sensor Connector [65]
(Under Bracket)
7. P&A Security Siren Connector [142] (Under Bracket)
2004 Touring: Fuel Injection 9-3
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Fuel
Pump
Spare
EFI System Relay
f2223x9x
INSTALLATION
1. Install relay in slots of fuse block. See Figure 9-3.
2. Engage tabs on fuse block with slots in bracket. Slide
fuse block up into cavity. Gently tug on conduit to verify
that fuse block is locked in place.
3. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
4. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
ECM Power
Figure 9-3. EFI Fuse Block
4. Gently pull on data link connector [91] to disengage from
arms on electrical bracket. See Figure 9-2.
5. Remove rubber protective plug from data link connector.
6. See DIGITAL TECHNICIAN (Part No. HD-44750) or the
2004 ELECTRICAL DIAGNOSTIC MANUAL (Part No.
99497-04) to use the data link connector for system
diagnosis and electrical troubleshooting.
7. Install protective plug in data link connector.
8. With the plug side down and in contact with tab, position
connector between arms on electrical bracket.
9. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
10. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
EFI SYSTEM RELAY
REMOVAL
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Locate painted white dot on inboard side of fuse block.
Pressing on dot, gently tug on conduit to release tabs on
fuse block from slots in bracket.
4. Pull relay from slots in fuse block. See Figure 9-3.
EFI FUSES
REMOVAL
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Locate painted white dot on inboard side of fuse block.
Pressing on dot, gently tug on conduit to release tabs on
fuse block from slots in bracket.
4. Pull fuses from slots in fuse block and inspect for damage. Replace fuse if the element is burned or broken.
Automotive type ATO fuses are used. See Figure 9-3.
NOTE
While a spare 15 amp fuse is located in the EFI fuse block,
one extra 10 amp and 15 amp fuse are also located in the
system fuse block cover. See Section
for more information.
8.3 SYSTEM FUSES
INSTALLATION
1. Insert fuse in the appropriate slot. See Figure 9-3.
2. Engage tabs on fuse block with slots in bracket. Slide
fuse block up into cavity. Gently tug on conduit to verify
that fuse block is locked in place.
3. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
4. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
ELECTRONIC CONTROL MODULE
REMOVAL
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
9-4 2004 Touring: Fuel Injection
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1. Vehicle Speed Sensor [65]
2. P&A Security Siren [142]
1
2
f2183x8x
2. Gently pull side cover from frame downtubes (no tools
required).
3. Depress external latch and use rocking motion to
remove ECM connector [78]. See Figure 9-2.
4. Remove two socket screws to detach ECM from electrical bracket.
INSTALLATION
1. Align holes in ECM with those in electrical bracket.
Install two socket screws and tighten to 50-60
(5.7-6.8 Nm). See Figure 9-2.
2. Install ECM connector [78]. Push connector halves
together until latch clicks.
3. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
4. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
in-lbs
Figure 9-4. Electrical Bracket (Inboard Side)
SECURITY SIREN CONNECTOR
REMOVAL
1. Remove right side saddlebag. See Section 2.25 SAD-
DLEBAG, REMOVAL.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Remove two flange nuts to release electrical bracket
from studs on side of battery box. See Figure 9-4.
INSTALLATION
1. Install security siren connector [142] and vehicle speed
sensor connector [65] on inboard side of electrical
bracket as shown in Figure 9-4. Be sure that conduit and
cables are properly routed or wires may be pinched during installation.
2. Slide electrical bracket onto studs at side of battery box.
3. Install flange nuts on studs and tighten to 36-48
(4.1-5.4 Nm).
4. Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place (no tools
required).
in-lbs
EFI HARNESS
For removal and installation instructions, see Section 8.32
WIRING HARNESSES AND CABLES, EFI HARNESS
(FUEL INJECTED).
5. Install right side saddlebag. See Section 2.25 SADDLE-
BAG, INSTALLATION.
2004 Touring: Fuel Injection 9-5
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SENSORS 9.3
GENERAL
Six sensors inform the ECM of the environmental and engine
operating factors influencing fuel and spark requirements.
The sensors are as follows:
Intake Air Temperature Sensor
●
Throttle Position Sensor
●
Manifold Absolute Pressure Sensor
●
●
Bank Angle Sensor (Internal to TSM/TSSM)
●
Crankshaft Position Sensor
Engine Temperature Sensor
●
INTAKE AIR TEMPERATURE SENSOR
See Section 9.5 INDUCTION MODULE ASSEMBLY,
INTAKE AIR TEMPERATURE SENSOR.
THROTTLE POSITION SENSOR
See Section 9.5 INDUCTION MODULE ASSEMBLY,
THROTTLE POSITION SENSOR.
MANIFOLD ABSOLUTE PRESSURE
SENSOR
f2256x8x
Stator
Connector [46]
Crankshaft
Position Sensor
Connector [79]
Figure 9-5. Voltage Regulator (Left Side View)
f2217x8x
Socket Screw
See Section 9.5 INDUCTION MODULE ASSEMBLY, MANI-
FOLD ABSOLUTE PRESSURE SENSOR.
BANK ANGLE SENSOR
See Section 8.17 TURN SIGNAL/SECURITY MODULE.
CRANKSHAFT POSITION SENSOR
REMOVAL
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Locate crankshaft position sensor connector [79], 2place Mini-Deutsch, fixed to bracket at bottom of voltage
regulator. See Figure 9-5.
3. Push connector toward right side of motorcycle to disengage small end of slot on attachment clip from T-stud on
bracket. Lift connector off T-stud.
4. Depress button on socket terminal side and pull apart
pin and socket halves.
Figure 9-6. Remove Sensor Mount Socket Screw
5. Remove allen head socket screw to free crankshaft position sensor mount from front left side of crankcase. Pull
sensor from bore. See Figure 9-6.
6. Pull sensor to draw convoluted tubing and connector out
from under voltage regulator.
7. Remove terminals from pin housing. See Figure 9-7.
9-6 2004 Touring: Fuel Injection
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f1699x9x
Sensor
Body Hex
Thermistor
O-Ring
Convoluted
Tubing
7. Place large end of slot on attachment clip over T-stud on
bracket. Push connector toward left side of motorcycle to
engage small end of slot.
8. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
ENGINE TEMPERATURE SENSOR
f2218x8x
Figure 9-7. Crankshaft Position Sensor
NOTE
For instructions on properly removing wire terminals, see
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING PINS.
8. Remove convoluted tubing from crankshaft position sensor cable.
INSTALLATION
1. Install convoluted tubing onto crankshaft position sensor
cable. See Figure 9-7.
2. Referencing the following table, install terminals into pin
housing.
Table 9-1. Crankshaft Position Sensor [79]
Wire Color
Red 1
Black 2
NOTE
For instructions on properly installing wire terminals, see
APPENDIX B.1 DEUTSCH ELECTRICAL CONNECTORS,
REMOVING/INSTALLING PINS.
Chamber Number
REMOVAL
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. On left side of motorcycle, pull back boot at back of front
cylinder to reveal engine temperature sensor connector
[90], 2-place Packard.
3. Pull external latch outward and use rocking motion to
remove connector.
4. Slide a 3/4 inch deepwell socket over the sensor body
hex and turn counter-clockwise to loosen. See Figure 9-
8. When sensor turns easily, pull out the deepwell socket
and remove sensor by hand.
INSTALLATION
1. Hand start threaded end of
cylinder head bore.
2. Slide 3/4 inch deepwell socket over sensor body hex and
tighten to 120-180
3. Install engine temperature sensor connector [90], 2place Packard, at back of front cylinder.
4. Pull boot over sensor to keep out dirt and debris.
5. Install maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, INSTALLATION.
in-lbs
new
temperature sensor into
(13.6-20.3 Nm).
3. Install
4. Push sensor into bore aligning hole in sensor mount with
5. Route connector and convoluted tubing under front
6. Mate pin and socket halves of crankshaft position sensor
new
O-ring in groove on sensor body. Apply a thin
film of clean H-D 20W50 engine oil to O-ring before
installation.
hole in spot face. Install allen head socket screw and
tighten to 90-120
engine stabilizer link to underside of voltage regulator.
connector [79]. See Figure 9-5.
in-lbs
(10.2-13.6 Nm). See Figure 9-6.
Figure 9-8. Engine Temperature Sensor
2004 Touring: Fuel Injection 9-7
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FUEL TANK (FUEL INJECTED) 9.4
Fuel Level Sender
GENERAL
See Figure 9-9. The fuel pump, fuel filter canister, fuel pressure regulator, and fuel level sender are attached to the canopy for easy removal and installation. The act of raising the
canopy automatically removes these items, thereby eliminating those tasks which used to be performed by reaching
inside the fuel tank. This arrangement minimizes the possibility of dropping or losing parts inside the tank, or adding contaminants (such as grease and oil) to the fuel supply.
The fuel tank assembly consists of the following components:
Fuel Tank
●
●
Canopy
●
Fuel Pump
Fuel Pressure Regulator
●
●
Fuel Filter Canister
●
Low Fuel Level Warning Lamp
●
Fuel Supply Check Valve
●
COMPLETE REMOVAL
FLHT/C/U/I, FLTRI
1WARNING1WARNING
Gasoline is extremely flammable and highly explosive.
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Inadequate safety
precautions could result in death or serious injury.
Fuel Level
Sender
and Float
Fuel Pump
Fuel Filter
Canister
Supply Fitting
(Check Valve)
Canopy
Fuel Pressure
Regulator
In-tank Tubing
(Fuel Pump to Filter Canister)
In-tank Tubing
(Fuel Pressure Regulator
to Supply Fitting)
f1969x9x
Figure 9-9. Fuel Tank Assembly (FLHT/C/U/I, FLTRI)
9-8 2004 Touring: Fuel Injection
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