INSTRUCTIONS - Harley
Contents
1. O Ring Fuel Tube 7 6 mn I D 2 6 mm thick Not sold Not sold Not sold Not sold Not sold Not sold Not sold 2 of 22. If the flange thickness is 6 mm 1 4 inch use the 14 mm 9 16 inch long screws 3 If the flange thickness is 9 mm 3 8 inch use the 17 mm 11 16 inch long screws 4 9 Using a T20 TORX drive head use two screws item 3 or 4 see note above from the kit to fasten the fuel rail to the induction module Alternately tighten the screws to 27 33 in Ibs 3 0 3 7 Nm NOTE Observe the threaded hole in the fuel rail before selecting the fuel tube mounting screw from the kit see the Service Parts illustration If the threaded hole is drilled through the top as shown in the illustration use the 17 mm 11 16 inch long screw 4 If the threaded hole is a blind hole use the 14 mm 9 16 inch long screws 3 1 of 2 10 Select the fuel tube clip 5 sealing washer 6 O ring 7 and the correct screw from the kit Align the hole in the fuel supply tube clip with the hole in the fuel rail Using a T20 TORX drive head install the screw and tighten to 27 33 in Ibs 3 0 3 7 Nm Rotate the fuel supply tube so that it angles downward A loose fuel tube will allow gasoline to leak Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury Verify that the clip is holding the fuel tube tight If it is not remove the items just assembled and clean the threads as necessary to ensure the fuel tube is tightly secured 11 See INDUCTION MODULE INSTALLATION
3. cMOTOR2 HARLEY DAVIDSON WY J02708 INSTRUCTIONS REV 10 01 2002 Kit Number 27635 01A INDUCTION MODULE HARDWARE KIT General This kit fits e all 2002 and later Fuel Injected FL Touring models e all 2001 and later Fuel Injected Softail models See the Service Parts illustration on the last page of these instructions for kit contents WARNING A Service Manual is necessary for installation of this kit The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper installa tion of this kit could result in death or serious injury NOTE A Service Manual for your model motorcycle is available from your Harley Davidson dealer Installation WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before proceed ing Inadequate safety precautions could result in death or serious injury Always disconnect the negative battery cable first If the positive battery cable should contact ground with the neg ative cable installed the resulting sparks may cause a bat tery explosion which could result in death or serious injury 1 Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first Gasoline is ext
4. in the Service Manual Assemble the throttle body and intake manifold using the large O ring 2 and two screws 4 from the kit Apply 1 2 drops of Loctite 290 Threadlocker to the end of each screw Tighten the screws to 27 33 in Ibs 3 0 3 7 Nm Install the induction module to the cylinder heads Always connect the positive battery cable first If the posi tive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 12 Connect the battery cables positive cable first WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could result in shifting during vehicle operation loss of control of vehicle death or serious injury 13 Refer to the Service Manual and follow instructions to install the seat 14 Start the motorcycle and check for proper engine opera tion and fuel leaks CANY e Service Parts Part No 27635 01A Date 10 02 Induction Module Hardware Kit Note Fuel tube mounting hole is not drilled through on some fuel rails a manifold J02708 o 3 4 i05123 Fuel tube Description Part No O Ring Injector 4 7 5 mm I D 3 5 mm thick O Ring Throttle Body to Intake Manifold Screw Torx Head M4 x 14mm 3 Screw Torx Head M4 x 17mm 5 Clip Fuel Tube Washer Sealing Fuel Tube
5. remely flammable and highly explosive When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Inadequate safety pre cautions can result in death or serious injury 2 Remove the induction module and separate the throttle body from the intake manifold See INDUCTION MOD ULE REMOVAL in the FUEL INJECTION section of the Service Manual 3 FL Touring models Refer to the Service Manual to remove the fuel rail and fuel supply tube The fuel tube clip and the washer and O ring beneath it can be dis carded 4 Remove the fuel injectors See FUEL INJECTORS REMOVAL in the Service Manual 5 See Figure 1 Remove and discard the two O rings from each of the fuel injectors 6 Apply a thin coat of clean engine oil to the new fuel injector O rings 1 from the kit Install the O rings onto the fuel injectors i05125 O Ring O Ring Electrical Connector Figure 1 Fuel Injector 7 With the electrical connector facing upward push the fuel injectors into the induction module bores Rotate the fuel injectors so that the electrical connectors are on the out board side 8 Push the fuel rail over the fuel injectors until the fuel rail flange contacts the boss on the induction module NOTE Measure the fuel rail mounting flange thickness before select ing the mounting screws from the kit see the Service Parts illustration dimension X
Download Pdf Manuals
Related Search