HOME
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
HOME
NOTES
9-2 2004 Touring: Fuel Injection
HOME
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
HOME
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
HOME
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
HOME
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
HOME
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
HOME
1WARNING1WARNING
1WARNING1WARNING
1WARNING1WARNING
Fuel
Pump
f2223x9x
Figure 9-10. EFI Fuse Block
1WARNING1WARNING
Gasoline will drain from the crossover hose 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.
CAUTION
Do not kink crossover hose or crimp shut using pliers or
similar tool. Damage to the rigid inner lining will occur.
1. Drain fuel tank as follows:
Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D.
Insert bolt in one end of hose and install hose clamp to
ensure that end is securely plugged. Using a side cutters, cut
clamp from one end of crossover hose beneath fuel tank.
Quickly replace crossover hose on fuel tank fitting with open
end of short hose while directing flow of gasoline from free
end of crossover hose into suitable container.
2. Remove seat. See Section 2.24 SEAT, REMOVAL.
1WARNING1WARNING
a. Remove the 15 amp fuel pump fuse. See Figure 9-
10. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 sec-
onds to remove remaining fuel from fuel lines.
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
4. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
5. Carefully cut anchored cable strap securing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
6. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws secure
console to clip nuts on the canopy bracket.
7. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment.
8. Lay a clean shop towel on forward part of rear fender.
9. Remove filler cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall filler
cap.
10. Depress button on socket side and remove fuel level
sender/fuel pump connector [141], 3-place Mini-Deutsch, at top of canopy.
11. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
A small amount of gasoline may 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.
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. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury.
3. Purge the fuel supply line of high pressure gas. Proceed
as follows:
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
12. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
2004 Touring: Fuel Injection 9-9
HOME
Fuel
Tank
Chrome
Sleeve
Figure 9-11. Fuel Supply Line Fitting
13. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
NOTE
The fuel tank mounting bolts have both an internal TORX
recess and an external hex, which allows them to be
removed with either a T40 TORX bit or a 1/2 inch open end/
box wrench. Use of the external hex allows the front mounting bolts to be removed without having to loosen or remove
the fairing lowers, if installed.
14. Remove fuel tank from vehicle.
f2021x9x
FLHR/C/S/I
CAUTION
When removing instrument console, exercise caution to
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
6. Secure instrument console to top of rear fender using
bungee cords.
7. Remove console mounting bolt from slot at top of canopy.
8. Gently pry fuel vapor vent tube from fitting.
9. At bottom left side of fuel tank, gently pull on convoluted
tubing to draw fuel gauge connector [117], 4-place Multilock, out of tunnel. Depress button on socket terminal
side and pull apart pin and socket halves.
1WARNING1WARNING
A small amount of gasoline may 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.
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
10. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
11. Remove fuel tank from vehicle.
1. See Section 9.4 FUEL TANK (FUEL INJECTED), COM-
PLETE REMOVAL, FLHT/C/U/I, FLTRI, steps 1-4.
2. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone. On FLHRSI models, removal of rear bolt also
releases instrument console bracket.
3. Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
4. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRSI models).
5. Raise instrument console and bend back flexible clamp
on canopy to release main harness conduit. Depress
button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
9-10 2004 Touring: Fuel Injection
INSTALLATION (AFTER COMPLETE REMOVAL)
FLHT/C/U/I, FLTRI
CAUTION
Exercise caution to avoid pinching the wiring harness
between the fuel tank and vehicle frame. Wire damage
may result in electrical problems.
1. Work fuel tank into position aligning front flange holes
with those in frame.
2. Slide
new
clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank (after removing
temporary plug). Crimp clamp.
HOME
1WARNING1WARNING
1WARNING1WARNING
Fuel
Tank
Fuel Pump,
Fuel Level
Sender Conduit
Main
Harness
Bundle
Console
Pod Conduit
Console
Pod
Fuel Vapor
Vent Tube
(To Vapor Valve)
Anchored
Cable Strap
FLHTCUI
f2007x9x
Fuel
Overflow
Hose
Main
Harness
Bundle
3. Start fuel tank front mounting bolts (with flat washers)
into left and right side of frame.
4. Install bolt (with flat washer) to secure rear of fuel tank to
frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).
5. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (2027 Nm).
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
6. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and insert neck of fuel supply line
fitting. While pushing up on bottom of fitting, pull down
on chrome sleeve until it “clicks” into the locked position.
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
Fuel
Tank
Console
Fuel Pump,
Fuel Level
Sender Conduit
Fuel Vapor
Vent Tube
(To Vapor Valve)
Main
Harness
Bundle
Anchored
Cable Strap
FLHT/C/I, FLTRI
Figure 9-12. Console Pod Cable/Hose Routing
(Top View)
f1739b9x
Fuel
Overflow
Hose
Main
Harness
Bundle
7. Connect fuel vapor vent tube to nipple on filler neck of
fuel tank.
8. Install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy.
9. Remove filler cap. Position console on canopy. Route
cables from beneath console as shown in Figure 9-12.
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
10. Install Allen head screw to fasten rear flange of console
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs
(2.8-3.4 Nm).
11. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30
12. Snap anchor of
frame backbone. Tighten cable strap capturing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube. See Figure 9-12. Cut any excess cable strap material.
Route fuel overflow hose inboard of wire bundles on right
side of frame, but do not capture in cable straps.
13. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96
new
cable strap into hole on left side of
NOTE
in-lbs
(6.8-10.9 Nm).
in-lbs
(2.8-3.4 Nm).
2004 Touring: Fuel Injection 9-11
HOME
14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
15. Install seat. See Section 2.24 SEAT, INSTALLATION.
FLHR/C/S/I
1. Work fuel tank into position aligning front flange holes
with those in frame.
Convoluted
Tubing
2. Slide
new
clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank (after removing
temporary plug). Crimp clamp.
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
3. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and insert neck of fuel supply line
fitting. While pushing up on bottom of fitting, pull down
on chrome sleeve until it “clicks” into the locked position.
1WARNING1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
4. Connect fuel vapor vent tube to fitting at top of canopy.
5. Slide head of console mounting bolt into slot at top of
canopy.
6. Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy. Bend flexible
clamp to capture main harness conduit.
7. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
8. Star
9. Install bolt (with flat washer) to secure rear of fuel tank to
10. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-
t fuel tank front mounting bolts (with flat washers)
into left and right side of frame.
frame backbone. On FLHRSI models, capture instrument console bracket during installation. Tighten bolt to
15-20 ft-lbs (20-27 Nm).
27 Nm).
8870
Figure 9-13. Fuel Gauge (FLHR/C/S)
11. Install acorn nut at top of instrument console and tighten
to 50-90
Phillips screw and large flat washer (absent on FLHRSI
models). Tighten screw to 36-60
12. Connect fuel gauge to main harness. Route pin housing
and convoluted tubing forward and then inboard
between front of crossover hose fitting and bottom of fuel
tank. Mate pin and socket halves of fuel gauge connector [117], 4-place Multilock. Feed connector into tunnel
of fuel tank. See Figure 9-13.
13. Snap anchor of
frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material. See Fig-
ure 9-12.
14. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96
15. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
16. Install seat. See Section 2.24 SEAT, INSTALLATION.
in-lbs
(5.7-10.2 Nm). If present, also install
in-lbs
(4.1-6.8 Nm).
new
cable strap into hole on left side of
in-lbs
(6.8-10.9 Nm).
PARTIAL 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.
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
9-12 2004 Touring: Fuel Injection
HOME
1WARNING1WARNING
CAUTION
1WARNING1WARNING
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.
2. Purge the fuel supply line of high pressure gas. Proceed
as follows:
a. Remove the 15 amp fuel pump fuse. See Figure 9-
10. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 sec-
onds to remove remaining fuel from fuel lines.
1WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
3. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
4. Carefully cut anchored cable strap securing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
5. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws secure
console to clip nuts on the canopy bracket.
6. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment.
7. Lay a clean shop towel on forward part of rear fender.
8. Remove filler cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall filler
cap.
9. Depress button on socket side and remove fuel level
sender/fuel pump connector [141], 3-place Mini-Deutsch, at top of canopy.
10. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
1WARNING1WARNING
A small amount of gasoline may 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.
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
11. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
12. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
NOTE
The fuel tank mounting bolts have both an internal TORX
recess and an external hex, which allows them to be
removed with either a T40 TORX bit or a 1/2 inch open end/
box wrench. Use of the external hex allows the front mounting bolts to be removed without having to loosen or remove
the fairing lowers, if installed.
13. Raise the fuel tank approximately 2 inches. Move the
fuel tank crossover hose to the rear of the ignition coil,
so that the tank can be raised an additional 2-3 inches.
Move fuel tank straight back and rest on frame backbone.
14. Obtain several 1 x 2 inch wooden blocks. Raise front and
rear of fuel tank off the frame backbone by placing
blocks in tunnel at bottom of tank.
FLHR/C/S/I
1. See Section 9.4 FUEL TANK (FUEL INJECTED), PAR-
TIAL REMOVAL, FLHT/C/U/I, FLTRI, steps 1-3.
2. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone. On FLHRSI models, removal of rear bolt also
releases instrument console bracket.
3. Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
4. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRSI models).
5. Raise instrument console and bend back flexible clamp
on canopy to release main harness conduit. Depress
button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
When removing instrument console, exercise caution to
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
2004 Touring: Fuel Injection 9-13
HOME
6. Secure instrument console to top of rear fender using
bungee cords.
7. Remove console mounting bolt from slot at top of canopy.
8. Gently pry fuel vapor vent tube from fitting at top of canopy.
9. At bottom left side of fuel tank, gently pull on convoluted
tubing to draw fuel gauge connector [117], 4-place Multilock, out of tunnel. Depress button on socket terminal
side and pull apart pin and socket halves. See Figure 9-
13.
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
5. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and insert neck of fuel supply line
fitting. While pushing up on bottom of fitting, pull down
on chrome sleeve until it “clicks” into the locked position.
1WARNING1WARNING
A small amount of gasoline may 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.
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
10. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
11. Raise the fuel tank approximately 2 inches. Move the
fuel tank crossover hose to the rear of the ignition coil,
so that the tank can be raised an additional 2-3 inches.
Move fuel tank straight back and rest on frame backbone.
12. Obtain several 1 x 2 inch wooden blocks. Raise front and
rear of fuel tank off the frame backbone by placing
blocks in tunnel at bottom of tank.
INSTALLATION (AFTER PARTIAL REMOVAL)
FLHT/C/U/I, FLTRI
1. Remove wooden blocks and move fuel tank toward its
installed position. While positioning fuel tank, move
crossover hose in front of ignition coil. Work fuel tank
into position aligning front flange holes with those in
frame.
2. Star
3. Install bolt (with flat washer) to secure rear of fuel tank to
4. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-
t fuel tank front mounting bolts (with flat washers)
into left and right side of frame.
frame backbone. Tighten bolt to 15-20 ft-lbs (20-27 Nm).
27 Nm).
1WARNING1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
6. Connect fuel vapor vent tube to fitting on filler neck of
fuel tank.
7. Install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy.
8. Remove filler cap. Position console on canopy. Route
cables from beneath console as shown in Figure 9-12.
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
9. Install Allen head screw to fasten rear flange of console
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
10. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube. Cut any excess cable strap material. See Figure 9-
12.
NOTE
Route fuel overflow hose inboard of wire bundles on right
side of frame, but do not capture in cable straps.
12. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
13. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
14. Install seat. See Section 2.24 SEAT, INSTALLATION.
9-14 2004 Touring: Fuel Injection
HOME
1WARNING1WARNING
CAUTION
1WARNING1WARNING
FLHR/C/S/I
1. Remove wooden blocks and move fuel tank toward its
installed position. While positioning fuel tank, move
crossover hose in front of ignition coil. Work fuel tank
into position aligning front flange holes with those in
frame.
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
2. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and insert neck of fuel supply line
fitting. While pushing up on bottom of fitting, pull down
on chrome sleeve until it “clicks” into the locked position.
1WARNING1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
3. Connect fuel vapor vent tube to fitting at top of canopy.
4. Slide head of console mounting bolt into slot at top of
canopy.
5. Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy. Bend flexible
clamp to capture main harness conduit.
6. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
7. Star
8. Install bolt (with flat washer) to secure rear of fuel tank to
9. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-
10. Install acorn nut at top of instrument console and tighten
11. Connect fuel gauge to main harness. Route pin housing
t fuel tank front mounting bolts (with flat washers)
into left and right side of frame.
frame backbone. On FLHRSI models, capture instrument console bracket during installation. Tighten bolt to
15-20 ft-lbs (20-27 Nm).
27 Nm).
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRSI
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
and convoluted tubing forward and then inboard
between front of crossover hose fitting and bottom of fuel
tank. Mate pin and socket halves of fuel gauge connector [117], 4-place Multilock. Feed connector into tunnel
of fuel tank. See Figure 9-13.
12. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material. See Fig-
ure 9-12.
13. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
15. Install seat. See Section 2.24 SEAT, INSTALLATION.
CONSOLE POD/CANOPY
FLHT/C/U/I, FLTRI
REMOVAL
Gasoline will drain from the crossover hose 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.
Do not kink crossover hose or crimp shut using pliers or
similar tool. Damage to the rigid inner lining will occur.
1. Drain fuel tank as follows:
Obtain a short section of hose with a 5/16 inch (7.9 mm)
I.D. Insert bolt in one end of hose and install hose clamp
to ensure that end is securely plugged. Cut clamp from
one end of crossover hose beneath fuel tank. Quickly
replace crossover hose on fuel tank fitting with open end
of short hose while directing flow of gasoline from free
end of crossover hose into suitable container.
2. Remove seat. See Section 2.24 SEAT, REMOVAL.
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.
3. Purge the fuel supply line of high pressure gas. Proceed
as follows:
2004 Touring: Fuel Injection 9-15
HOME
f1955x9x
Convoluted
Tube
Figure 9-14. Raise Canopy and Remove Tube
(FLHT/C/U/I, FLTRI)
a. Remove the 15 amp fuel pump fuse. See Figure 9-
10. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 sec-
onds to remove remaining fuel from fuel lines.
1WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
4. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
5. Carefully cut anchored cable strap securing main harness bundle, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube to left side of frame backbone.
6. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws secure
console to clip nuts on the canopy bracket.
7. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment.
8. Lay a clean shop towel on forward part of rear fender.
9. Remove filler cap from neck of fuel tank. Remove console and lay upside down on shop towel. Reinstall filler
cap.
10. Depress button on socket side and remove fuel level
sender/fuel pump connector [141], 3-place Mini-Deutsch, at top of canopy.
11. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
12. Using a T20 TORX bit, remove ten screws around the
outer edge of the canopy. Discard screws.
13. Raise canopy slightly to access top fitting (inlet port) at
back of fuel pressure regulator. Using a side cutters, cut
hose clamp and remove convoluted tube. Exercise caution to avoid cutting or damaging tube or dropping
pieces of cut clamp into fuel tank. See Figure 9-14.
14. Remove canopy from fuel tank (with attached fuel pressure regulator, fuel filter canister, fuel pump and fuel
level sender).
A spring-loaded hinge on the fuel pump bracket facilitates removal of the assembly. For best results, press
down on top of fuel pump with index finger or end of
screwdriver, and after raising canopy slightly, rotate on
hinge in a counterclockwise direction. When canopy is at
a 45˚ angle to top of fuel tank, carefully pull assembly
from left side lobe of fuel tank. See Figure 9-16.
15. Remove and discard canopy gasket. Verify that sealing
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
INSTALLATION
1. Obtain new canopy gasket. With the locator bump on the
gasket OD toward the front, position gasket at bottom of
canopy. Start four nubs on gasket into holes in canopy.
Moving to top of canopy, alternately grasp each nub and
pull through hole.
CAUTION
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will
result in erroneous gauge readings.
2. While holding fuel pump stationary, raise canopy slightly
and rotate on hinge 90˚ in a counterclockwise direction.
3. Holding assembly so that canopy is at a 45˚ angle to top
of fuel tank, insert assembly into left side lobe of fuel
tank. The spring-loaded hinge on the fuel pump bracket
automatically returns assembly to its installed position
inside fuel tank.
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
4. Raise canopy slightly and slide new hose clamp onto
free end of convoluted tube. Install tube onto top fitting
(inlet port) at back of fuel pressure regulator. Crimp
clamp. See Figure 9-14.
9-16 2004 Touring: Fuel Injection
HOME
f1957x9x
f1956x9x
Sealing
Device
1
79
63
5
4
810
f1963x9x
10. Open fuel door on console. Install two Allen head screws
to secure front of console to clip nuts on canopy bracket.
Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm).
11. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundles, console pod conduit (Ultra models only),
fuel level sender/fuel pump conduit, and fuel vapor vent
tube. See Figure 9-12. Cut excess cable strap material.
12. Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank. Crimp clamp.
13. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
f2011x9x
2
Figure 9-15. Canopy Sealing Screws and Torque
Sequence
1WARNING1WARNING
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity
resulting in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
NOTE
Check canopy screws for proper sealing devices. Screws
must have a bonded seal on underside of head. Replace
screws if seal is missing or damaged. See Figure 9-15.
5. While pushing down on the canopy, align holes in can-
opy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
Figure 9-15.
6. Connect fuel vapor vent tube to fitting on filler neck of
fuel tank.
7. Install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy.
8. Remove filler cap. Position console on canopy. Route
cables from beneath console as shown in Figure 9-12.
Be sure that hoses and wires are not pinched by the
console during installation. Reinstall filler cap.
9. Install Allen head screw to fasten rear flange of console
to clip nut on fuel tank weldment. Tighten screw to 25-30
in-lbs (2.8-3.4 Nm).
Figure 9-16. Remove Canopy From Vehicle (FLHR/C/S/I)
2004 Touring: Fuel Injection 9-17
HOME
14. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
15. Install seat. See Section 2.24 SEAT, INSTALLATION.
1WARNING1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
INSTRUMENT CONSOLE/CANOPY
FLHR/C/S/I
REMOVAL
1WARNING1WARNING
Gasoline will drain from the crossover hose 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.
CAUTION
Do not kink crossover hose or crimp shut using pliers or
similar tool. Damage to the rigid inner lining will occur.
1. Drain fuel tank as follows:
Obtain a short section of hose with a 5/16 inch (7.9 mm)
I.D. Insert bolt in one end of hose and install hose clamp
to ensure that end is securely plugged. Cut clamp from
one end of crossover hose beneath fuel tank. Quickly
replace crossover hose on fuel tank fitting with open end
of short hose while directing flow of gasoline from free
end of crossover hose into suitable container.
2. Remove seat. See Section 2.24 SEAT, REMOVAL.
1WARNING1WARNING
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.
3. Purge the fuel supply line of high pressure gas. Proceed
as follows:
a. Remove the 15 amp fuel pump fuse. See Figure 9-
10. If necessary, see Section 9.2 ELECTRICAL
BRACKET ASSEMBLY, EFI FUSES, REMOVAL.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 sec-
onds to remove remaining fuel from fuel lines.
4. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
5. Carefully cut anchored cable strap securing main harness bundle, instrument console conduit, and fuel vapor
vent tube to left side of frame backbone.
6. Remove acorn nut from instrument console. If present,
also remove Phillips screw and large flat washer (absent
on FLHRSI models).
7. On FLHRSI models only, remove bolt (with flat washer)
to free rear of fuel tank from frame backbone. Removal
of rear bolt also releases instrument console bracket.
8. Raise instrument console and bend back flexible clamp
on canopy to release main harness conduit. Depress
button on socket side and remove fuel level sender/fuel
pump connector [141], 3-place Mini-Deutsch.
CAUTION
When removing instrument console, exercise caution to
avoid damaging speedometer unit. Wrap console in a
clean, dry shop towel to prevent damage.
9. Secure instrument console to top of rear fender using
bungee cords.
10. Remove console mounting bolt from slot at top of canopy.
11. Gently pry fuel vapor vent tube from fitting at top of canopy.
12. Using a T20 TORX bit, remove ten screws around the
outer edge of the canopy. Discard screws.
13. Raise canopy slightly to access top fitting (inlet port) at
back of fuel pressure regulator. Using a side cutters, cut
hose clamp and remove convoluted tube. Exercise caution to avoid cutting or damaging tube or dropping
pieces of cut clamp into fuel tank. See Figure 9-14.
14. Remove canopy from fuel tank (with attached fuel pressure regulator, fuel filter canister, fuel pump and fuel
level sender).
A spring-loaded hinge on the fuel pump bracket facilitates removal of the assembly. For best results, press
down on top of fuel pump with index finger or end of
screwdriver, and after raising canopy slightly, rotate on
hinge in a counterclockwise direction. When canopy is at
a 45˚ angle to top of fuel tank, carefully pull assembly
from left side lobe of fuel tank. See Figure 9-16.
15. Remove and discard canopy gasket. Verify that sealing
devices from screws are not lodged in canopy holes.
Remove and discard devices if present.
9-18 2004 Touring: Fuel Injection
HOME
INSTALLATION
1. Obtain new canopy gasket. With the locator bump on the
gasket OD toward the front, position gasket at bottom of
canopy. Start four nubs on gasket into holes in canopy.
Moving to top of canopy, alternately grasp each nub and
pull through hole.
CAUTION
Exercise care to avoid bending float rod of fuel level
sender during installation. Be sure to position float rod
to the right of the fuel gauge drain tube or it will be bent
during installation of the canopy. A bent float rod will
result in erroneous gauge readings.
2. While holding fuel pump stationary, raise canopy slightly
and rotate on hinge 90˚ in a counterclockwise direction.
3. Holding assembly so that canopy is at a 45˚ angle to top
of fuel tank, insert assembly into left side lobe of fuel
tank keeping the float rod positioned to the right of the
fuel gauge drain tube. The spring-loaded hinge on the
fuel pump bracket automatically returns assembly to its
installed position inside fuel tank.
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
8. Moving instrument console toward installed position,
install fuel level sender/fuel pump connector [141], 3place Mini-Deutsch, at top of canopy. Bend flexible
clamp to capture main harness conduit.
9. Align hole in instrument console with console mounting
bolt and place into position on fuel tank.
10. Install acorn nut at top of instrument console and tighten
to 50-90 in-lbs (5.7-10.2 Nm). If present, also install
Phillips screw and large flat washer (absent on FLHRSI
models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).
11. On FLHRSI models only, install bolt (with flat washer) to
secure rear of fuel tank and instrument console bracket
to frame backbone. Tighten bolt to 15-20 ft-lbs (20-27
Nm).
12. Snap anchor of new cable strap into hole on left side of
frame backbone. Tighten cable strap capturing main harness bundle, instrument console conduit, and fuel vapor
vent tube. Cut any excess cable strap material.
13. Slide new clamp onto free end of crossover hose. Running hose beneath frame backbone, install hose onto fitting at bottom front of fuel tank. Crimp clamp.
14. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
15. Install the 15 amp fuel pump fuse. See Figure 9-10. If
necessary, see Section 9.2 ELECTRICAL BRACKET
ASSEMBLY, EFI FUSES, INSTALLATION.
16. Install seat. See Section 2.24 SEAT, INSTALLATION.
4. Raise canopy slightly and slide new hose clamp onto
free end of convoluted tube. Install tube onto top fitting
(inlet port) at back of fuel pressure regulator. Crimp
clamp. See Figure 9-14.
1WARNING1WARNING
Always use new screws when installing the canopy.
Reusing old screws may compromise sealing integrity
resulting in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
NOTE
Check canopy screws for proper sealing devices. Screws
must have a bonded seal on underside of head. Replace
screws if seal is missing or damaged. See Figure 9-15.
5. While pushing down on the canopy, align holes in can-
opy with those in fuel tank. Hand start ten new T20
TORX screws in perimeter of canopy. Tighten screws to
18-24 in-lbs (2.0-2.7 Nm) using the pattern shown in
Figure 9-15.
6. Connect fuel vapor vent tube to fitting at top of canopy.
7. Slide head of console mounting bolt into slot at top of
canopy.
FUEL FILTER CANISTER
Replace the fuel filter canister every 25,000 miles (40,000
km) . Proceed as follows:
REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2. Release fuel filter canister as follows:
a. Pull wireform to release from slots on fuel filter can-
ister bracket. See A of Figure 9-17.
b. Use hinge to swing wireform out of the way. Move
canister bracket forward to disengage tab from slot
on canopy weldment. See B of Figure 9-17.
c. Pull fitting on canister from fuel pressure regulator
assembly. See C of Figure 9-17.
3. Using a side cutters, cut hose clamp and remove convoluted tube from inlet port at side of fuel filter canister.
Exercise caution to avoid cutting or damaging tube. Discard fuel filter canister.
2004 Touring: Fuel Injection 9-19
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INSTALLATION
A
f1940x9x
Pull wireform from slots in canister bracket.
B
CAUTION
Do not replace tubes inside of fuel tank with ordinary
bulk hose. All internal lines must be replaced with the
special original equipment convoluted nylon tubes. Bulk
hose will degrade when immersed in gasoline (particularly stale gasoline), resulting in contamination of the
fuel supply. Use of contaminated fuel will cause starting
and driveability problems and possible vehicle damage.
1. If present, remove and discard plastic caps from fittings
of new fuel filter canister.
2. Slide new hose clamp onto free end of convoluted tube
(from fuel pump). Install tube onto inlet port at side of
fuel filter canister. If necessary, use a little isopropyl
alcohol or glass cleaner to aid installation. Crimp clamp.
3. Install fuel filter canister as follows:
a. Install new O-ring onto fitting of fuel filter canister.
Insert fitting into fuel pressure regulator assembly,
so that inlet port is on fuel pump side. See C of Fig-
ure 9-17.
b. Slide tab on canister bracket into slot of canopy
weldment until bump on bracket engages depression at side of canister. See B of Figure 9-17.
c. Use hinge to rotate wireform over canister bracket.
Press on wireform until it fully engages slots on canister bracket. See A of Figure 9-17.
f1945x9x
Pull canister bracket from canopy weldment.
C
f1944x9x
Pull canister from fuel pressure regulator.
Figure 9-17. Remove Fuel Filter Canister (FLHR/C/S/I)
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
4. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION.
FUEL PRESSURE REGULATOR
REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2. See FUEL FILTER CANISTER, REMOVAL, step 2.
3. Slide fuel pressure regulator assembly forward to free
arms from catches on canopy weldment. See Figure 9-
18.
9-20 2004 Touring: Fuel Injection
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CAUTION
Screwdriver
8399
f1943x9x
Figure 9-18. Remove Fuel Pressure Regulator
(FLHR/C/S/I)
5. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION.
FUEL PUMP
REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2. Depress external latch and remove electrical connector
at top of fuel pump.
3. Using a side cutters, cut hose clamp and pull convoluted
tube from fuel pump outlet port. Exercise caution to
avoid cutting or damaging tube (and cracking or breaking outlet port).
4. Remove T15 TORX screw and pull fuel level sender from
post on fuel pump bracket.
5. Release end of return spring from hook on fuel pump
bracket.
Housing
f1931x9x
Figure 9-19. Fuel Pressure Regulator Assembly
4. Remove fuel pressure regulator from housing. To overcome the resistance of two O-rings, insert blade of small
screwdriver into gap between regulator and housing and
gently pry regulator out. See Figure 9-19.
5. Inspect O-rings for cuts, tears or general deterioration.
Replace the O-rings if they have taken a definite set.
O-Ring
INSTALLATION
1. Apply a thin coat of clean engine oil to new O-rings.
Install O-rings in grooves of fuel pressure regulator. See
Figure 9-19.
2. Install fuel pressure regulator into housing.
3. Fit fuel pressure regulator assembly into canopy weldment engaging arms in catches. See Figure 9-18.
4. See FUEL FILTER CANISTER, INSTALLATION, step 3.
Be absolutely certain fuel pump is faulty before removing hinge from support arm. Hinge is damaged during
removal and requires replacement of the fuel pump and
bracket assembly.
6. Insert flat tip screwdriver at location shown in Figure 9-
20. Carefully crack plastic webbing at top of hinge and
remove from support arm. Discard fuel pump and
bracket assembly.
7. Inspect the condition of the fuel pump wiring. If the wiring needs to be replaced, see FUEL PUMP/FUEL
LEVEL SENDER WIRING on the next page.
Figure 9-20. Crack Hinge to Remove From Support Arm
2004 Touring: Fuel Injection 9-21
HOME
INSTALLATION
1. Obtain new fuel pump and bracket assembly. Install new
hinge at top of fuel pump bracket, so that opening of
support arm slot is on the fuel level sender mount side.
2. Slide end of support arm into slot at top of hinge. Pull on
hinge to verify that it is locked by pin on support arm.
Install free end of return spring onto hook on fuel pump
bracket.
CAUTION
Carefully inspect end of convoluted tube for cuts, tears,
holes or other damage. Replace tube if any damage is
found. Even the smallest hole can cause a reduction in
fuel pressure.
3. Slide new hose clamp onto free end of convoluted tube
(to fuel filter canister inlet). Install tube onto outlet port of
fuel pump. Crimp clamp, but exercise caution to avoid
cracking or breaking outlet port.
4. Install electrical connector at top of fuel pump. Gently
tug on connector to verify that external latch is locked
and connector will not come free of terminals.
5. Align two holes in fuel level sender with threaded hole
and post on fuel pump bracket. Install T15 TORX screw
in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).
6. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION.
f1946x9x
Push
Pull
To disengage tabs from windows, simultaneously
pull on one safety pin while pushing on the other.
Pull terminals from wire block and cut.
FUEL PUMP/FUEL LEVEL SENDER WIRING
CAUTION
Do not replace the special teflon coated fuel pump/fuel
level sender wiring with ordinary bulk wire. Ordinary
insulation materials may deteriorate when in contact
with gasoline.
NOTE
Damaged fuel pump and/or fuel level sender wiring requires
replacement of the fuel level sender unit. See FUEL LEVEL
SENDER on this page.
FUEL LEVEL SENDER
REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
f1930x9x
Figure 9-21. Remove Wire Block and Cut Terminals
2. If present, cut cable strap to release wiring at bottom of
support arm.
3. Unwind spiral tubing from fuel pump and fuel level
sender wiring.
4. Depress external latch and remove electrical connector
at top of fuel pump.
5. At bottom of canopy, remove socket terminal from spade
contact on connector clip.
6. Remove T15 TORX screw and pull fuel level sender from
post on fuel pump bracket.
9-22 2004 Touring: Fuel Injection
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7. Remove socket terminals from 3-place Mini-Deutsch
connector on canopy. Proceed as follows:
NOTE
For additional clearance, pull wireform to release from slots
on fuel filter canister bracket, and then use hinge to swing
wireform out of the way. Move canister bracket forward to disengage tab from slot on canopy weldment. Remove socket
terminal from spade contact on connector clip.
a. At underside of canopy, take note of the rectangular
opening or window on each side of the connector
body. Now take note of the tab inside each window.
b. Obtain two safety pins. On each side of connector
body, insert a safety pin between body and wire
block until end of each pin appears in window. To
disengage tabs from windows, gently pull on one
safety pin while pushing on the other. See upper
frame of Figure 9-21. With tabs released, gently tug
on wires to release wire block from connector body.
c. Pull the wire socket terminals out of the wire block.
See lower frame of Figure 9-21. Cut off the socket
terminals and back the wires out of the wire block.
d. Insert wire block back into connector body until tabs
lock in windows. One corner of wire block and connector body is square to prevent improper installation.
INSTALLATION
1. Insert socket terminals of new wiring into wire block.
Ta ke note of the table below for wire locations.
Table 9-2. Fuel Level Sender/Fuel Pump
Connector [141], 3-Place Mini-Deutsch
Chamber Wire Color Function
1Orange Pump Power
2Yellow Sender Output
3Black Ground
NOTE
A series of dots are molded into the wire end of the block to
indicate wire location, one dot indicating chamber 1, two dots
chamber 2, three dots chamber 3. (Wire location numbers
are also stamped below the terminals inside the Mini-Deutch
pin housing.)
5. Install electrical connector at top of fuel pump. Gently
tug on connector to verify that external latch is locked
and connector will not come free of terminals.
6. Wind spiral tubing around fuel pump (and fuel level
sender) wiring.
7. Install new cable strap capturing wiring at bottom of support arm. Cut any excess cable strap material.
8. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION.
CANOPY CONNECTOR/O-RING
REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, or INSTRUMENT CONSOLE/CANOPY,
FLHR/C/S/I, REMOVAL.
2. At bottom of canopy, remove socket terminal from spade
contact on connector clip.
3. Remove wire block from connector body as described
under FUEL LEVEL SENDER, REMOVAL, steps 7(a)-
7(b), on this page.
4. Slide connector clip from slots on connector body.
Remove connector body from canopy.
5. Remove O-ring from groove on connector body.
INSTALLATION
1. Apply a very thin film of clean H-D 20W50 engine oil to
O-ring. Install O-ring in groove of connector body.
2. Fit connector body into hole at top of canopy. At underside of canopy, install connector clip engaging slots in
connector body.
3. Insert wire block back into connector body until tabs lock
in windows. One corner of wire block and connector
body is square to prevent improper installation.
4. Install socket terminal onto spade contact on connector
clip.
5. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, or INSTRUMENT CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION.
2. Gently tug on wires to verify that they will not back out of
wire block.
3. Install socket terminal onto spade contact on connector
clip.
4. Align two holes in fuel level sender with threaded hole
and post on fuel pump bracket. Install T15 TORX screw
in upper hole and tighten to 25-35 in-lbs (2.8-4.0 Nm).
FUEL SUPPLY CHECK VALVE/TUBE
NOTE
The in-tank check valve is housed in the quick-connect fitting.
The check valve prevents the fuel tank from draining when
the external supply line is disconnected.
2004 Touring: Fuel Injection 9-23
HOME
Convoluted
Tube
O-Ring
Body Hex
Chrome Sleeve
Figure 9-22. Supply Check Valve (Quick-Connect Fitting)
REMOVAL
1. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
REMOVAL, steps 1-13, or INSTRUMENT CONSOLE/
CANOPY, FLHR/C/S/I, REMOVAL, steps 1-12.
1WARNING1WARNING
SUPPLY CHECK VALVE/TUBE
3. Slide a 7/8 inch deepwell socket over chrome sleeve
engaging hex on quick-connect fitting. See Figure 9-22.
Looking down at top of fuel tank, rotate fitting in a cloc
wise direction until it turns easily. Remove the fitting by
hand drawing convoluted tube out through hole at bottom of fuel tank.
f2048x9x
k-
A small amount of gasoline may 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.
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
2. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect. See Figure 9-11.
1WARNING1WARNING
A small amount of gasoline may drain from the fuel tank
when the quick-connect fitting is removed. Thoroughly
wipe up any spilled fuel immediately. Dispose of rags in
a suitable manner. Inadequate safety precautions could
result in death or serious injury.
INSTALLATION
CAUTION
Carefully inspect convoluted tube for cuts, tears, holes
or other damage. Replace tube (with attached quick-connect fitting) if any damage is found. Even the smallest
hole can cause a reduction in fuel pressure.
1. Apply a very thin film of clean H-D 20W50 engine oil to
new O-ring. Slide O-ring down convoluted tube and into
groove of new quick-connect fitting. See Figure 9-22.
2. Feeding convoluted tube through hole at bottom of fuel
tank, hand thread quick-connect fitting into bore. Looking down at top of fuel tank, rotate fitting in a counterclockwise direction until snug.
3. Slide a 7/8 inch deepwell socket over chrome sleeve
engaging hex on quick-connect fitting. Tighten fitting to
22-26 ft-lbs (29.8-35.3 Nm).
9-24 2004 Touring: Fuel Injection
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1WARNING1WARNING
1WARNING1WARNING
Exercise caution to avoid twisting the fuel supply line fitting, as any cracks in the plastic construction of the line
can result in gas leaks. Gas leakage can cause fire or
explosion which could result in death or serious injury.
4. Pull up on chrome sleeve of quick-connect fitting and
insert neck of fuel supply line fitting. While pushing up on
bottom of fitting, pull down on chrome sleeve until it
“clicks” into the locked position.
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line fitting will verify this condition. Gasoline is extremely flammable and
highly explosive. Inadequate safety precautions could
result in death or serious injury.
5. See CONSOLE POD/CANOPY, FLHT/C/U/I, FLTRI,
INSTALLATION, steps 4-15, or INSTRUMENT CONSOLE/CANOPY, FLHR/C/S/I, INSTALLATION, steps 4-
14.
2004 Touring: Fuel Injection 9-25
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NOTES
9-26 2004 Touring: Fuel Injection
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