Removal
Warning! Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Warning! Gasoline can drain from quick-connect fitting when removing fuel line. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner.
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.4 FUEL TANK: XL MODELS.
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
2. Remove main fuse.
3. Remove air cleaner assembly. See 4.3 AIR CLEANER ASSEMBLY.
4. Remove seat.
5. Pull fuel tank back to access induction module.
- a. Loosen (but do not remove) front fuel tank mounting screw.
- b. Remove rear fuel tank mounting screw, washers and nut.
- c. Carefully pivot rear of fuel tank upward and prop in position. See 4.4 FUEL TANK: XL MODELS.
6. See Figure 4-31. Remove screw (2) and mounting bracket (1).
![](https://motoinstruction.ru/img/harley/12/118066.jpg)
Figure 4-31. Induction module mounting bracket: 1. Mounting bracket; 2. Screw
7. See Figure 4-32. Unplug the following connectors:
- a. Front fuel injector (4) connector [84],
- b. Rear fuel injector (5) connector [85],
- c. TMAP sensor (6) connector [80],
- d. IAC (7) connector [87],
- e. TPS (8) connector [88].
![](https://motoinstruction.ru/img/harley/12/118067.jpg)
Figure 4-32. Induction module assembly: 1. Induction module; 2. Intake manifold; 3. Throttle cable bracket; 4. Front fuel injector [84A]; 5. Rear fuel injector [85A]; 6. TMAP sensor [80A]; 7. IAC [87A]; 8. TPS [88A]; 9. Purge hose fitting (EVAP controlled models); 10. Fuel supply hose; 11. Throttle wheel; 12. Fuel rail
8. EVAP Controlled Models: remove purge hose from fitting (9) on induction module (1).
9. See Figure 4-33. Slide rubber boot off idle control cable assembly (1).
![](https://motoinstruction.ru/img/harley/12/118068.jpg)
Figure 4-33. Idle control cable adjustment: 1. Idle control (pull close) cable assembly; 2. Cable adjuster; 3. Jamnut
10. Loosen jamnut (3).
11. Loosen cable adjuster as far as possible to provide maximum slack in idle cable.
12. See Figure 4-34. Loosen two screws (2) securing intake manifold to heads on left side of vehicle, but do not remove screws.
![](https://motoinstruction.ru/img/harley/12/118069.jpg)
Figure 4-34. Intake manifold mounting screws: left side: 1. Intake manifold; 2. Screw (2)
13. See Figure 4-35. Remove two screws (3) securing intake manifold to heads on right side of vehicle.
![](https://motoinstruction.ru/img/harley/12/118070.jpg)
Figure 4-35. Intake manifold mounting screws: right side: 1. Induction module; 2. Intake manifold; 3. Screw (2); 4. Mounting flange (2)
14. Pull mounting flanges (4) away from heads as much as possible and pull induction module and intake manifold assembly toward the right side, away from vehicle.
![](https://motoinstruction.ru/img/harley/12/118071.jpg)
Figure 4-36. Removing/installing throttle cable: 1. Throttle cable housing; 2. Throttle/idle cable bracket; 3. Cable guide; 4. Slot; 5. Throttle cable; 6. Cable barrel; 7. Throttle wheel; 8. Slot
15. See Figure 4-35. Remove throttle cable (5) from throttle wheel (7):
- a. Lift throttle cable housing (1) up out of cable guide (3) in throttle/idle cable bracket (2).
- b. Slide throttle cable (5) out through slot (4) in cable guide.
- c. Unwind throttle cable from groove in throttle wheel (7).
- d. Slide cable out through slot (8) and remove throttle cable barrel (6) from throttle wheel.
16. See Figure 4-37. In a similar fashion, remove idle cable (3) from throttle wheel (6):
- a. Lift idle cable housing (1) and spring (2) up out of cable guide (7) in throttle/idle cable bracket.
- b. Slide idle cable (3) out through slot in cable guide.
- c. Unwind idle cable from groove in throttle wheel (6).
- d. Slide cable out through slot (5) and remove idle cable barrel (4) from throttle wheel.
![](https://motoinstruction.ru/img/harley/12/118072.jpg)
Figure 4-37. Removing/installing idle cable: 1. Idle cable housing; 2. Spring; 3. Idle cable; 4. Cable barrel; 5. Slot; 6. Throttle wheel; 7. Cable guide
17. Remove induction module and intake manifold from vehicle.
Disassembly
PART NUMBER | TOOL NAME |
HD-25070 | HEAT GUN |
Warning! Gasoline can drain from the fuel line when disconnected from induction module. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner.
1. Remove fuel hose, fuel rail and fuel injectors. See 4.15 FUEL INJECTORS.
2. See Figure 4-38. Remove screws (1,2) and cable bracket (3) from induction module (4).
![](https://motoinstruction.ru/img/harley/12/118073.jpg)
Figure 4-38. Removing/installing cable bracket: 1. Screw; 2. Screw; 3. Cable bracket; 4. Induction module
Note. When removing the IAC, the mounting screws MUST be heated to soften the thread sealant and avoid breakage during removal. Use ONLY HEAT GUN (Part No. HD-25070) to heat the screws. NEVER use an open flame.
3. Remove the following assemblies:
- a. TPS. See 4.6 THROTTLE POSITION SENSOR (TPS)
- b. TMAP sensor. See 4.11 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR.
- c. IAC. See 4.10 IDLE AIR CONTROL (IAC).
4. See Figure 4-39. Remove two screws (3) to separate induction module (1) from intake manifold (2). Discard Oring (4).
![](https://motoinstruction.ru/img/harley/12/118074.jpg)
Figure 4-39. Induction module assembly: 1. Induction module; 2. Intake manifold; 3. Screw (2); 4. O-ring; 5. Groove
Note. At this level of disassembly, induction module contains no more serviceable parts. If induction module is determined to be damaged or defective, replace it.
Assembly
FASTENER | TORQUE VALUE | |
Induction module screw: XL models | 35 in·lbs | 4.0 Nm |
IAC mounting screw: XL Models | 60 in·lbs | 6.8 Nm |
Induction module cable bracket screw: XL Models | 60 in·lbs | 6.8 Nm |
1. See Figure 4-39. Place new O-ring (4) into groove (5) in induction module (1) mating surface.
2. Mate induction module to intake manifold (2). Secure with two screws (3). Tighten screws to 35 in·lbs (4.0 Nm).
3. Install the following assemblies:
- a. TPS. See 4.6 THROTTLE POSITION SENSOR (TPS)
- b. TMAP sensor. See 4.11 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR.
- c. IAC. See 4.10 IDLE AIR CONTROL (IAC).
Note. Do not install IAC mounting screw on throttle wheel side of induction module until cable bracket is installed. Install other IAC mounting screw but do not tighten at this time.
4. See Figure 4-38. Install cable bracket (3) onto induction module (4):
- a. Obtain new screws (1, 2) or apply LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue) to existing screws.
- b. Install both screws finger-tight.
- c. Tighten both IAC mounting screws to 60 in·lbs (6.8 Nm). Tighten side screw (1) to 60 in·lbs (6.8 Nm).
5. Install fuel injectors, fuel rail and fuel hose. See 4.15 FUEL INJECTORS.
Installation
FASTENER | TORQUE VALUE | |
Induction module mounting bracket screw: XL models | 90-120 in·lbs | 10.2-13.6 Nm |
Intake manifold mounting screw: XL models | 96-120 in·lbs | 10.9-13.6 Nm |
Fuel tank fasteners: XL Models | 15-20 ft·lbs | 20.3-27.1 Nm |
1. See Figure 4-34. Make sure two mounting screws (2) are screwed into heads two or three turns.
2. See Figure 4-40. Install mounting flanges (1) on intake manifold (5) with counterbore (2) facing away from manifold and open slotted ends of flanges facing away from induction module (6).
![](https://motoinstruction.ru/img/harley/12/118075.jpg)
Figure 4-40. Installing mounting flange and seal: 1. Mounting flange (2); 2. Counterbore; 3. Seal (2); 4. Beveled edge; 5. Intake manifold; 6. Induction module
3. Place a new seal (3) into each mounting flange with the beveled edge (4) facing the mounting flange counterbore.
Note. When induction module is positioned on manifold mounting screws, Verify the flanges are correctly installed on the manifold. Verify the rubber seals are in place.
4. Place induction module assembly in position between engine heads. Slide open slotted ends of mounting flanges under heads of two mounting screws on left side of engine.
5. See Figure 4-35. Holding induction module/intake manifold assembly in place, install two mounting screws (3) into remaining mounting flange holes. Tighten all four screws finger-tight.
6. See Figure 4-31. Install mounting bracket (1) and screw (2). Tighten screw finger-tight.
7. Temporarily install two breather screws through mounting bracket. Thread breather screws into cylinder heads finger-tight. This will properly line up induction module assembly.
8. Tighten mounting bracket screws to 90-120 in·lbs (10.213.6 Nm).
9. Tighten all four intake manifold mounting screws to 96120 in·lbs (10.9-13.6 Nm).
10. See Figure 4-37. Install idle cable barrel (4) into throttle wheel (6). Slide idle cable (3) through slot (5) and wind around groove in throttle wheel.
11. Pull cable through slot in cable guide (7). Slide spring (2) and end of idle cable housing (1) down into cable guide.
12. See Figure 4-36. Install throttle cable barrel (6) into throttle wheel (7). Slide throttle cable through slot (8) and wind around groove in throttle wheel.
13. Pull cable through slot (4) in cable guide (3). Slide end of throttle cable housing (1) down into cable guide.
14. Adjust throttle and idle cables. See 1.13 THROTTLE CONTROL.
15. EVAP Controlled Models: See Figure 4-41. Install purge hose onto fitting (2) on induction module (1).
![](https://motoinstruction.ru/img/harley/12/118076.jpg)
Figure 4-41. Purge hose fitting: CA models: 1. Induction module; 2. Purge hose (to canister) fitting
16. See Figure 4-42. Plug in the following connectors:
- a. Front fuel injector (1) connector [84],
- b. Rear fuel injector (2) connector [85],
- c. TMAP sensor (3) connector [80],
- d. IAC (4) connector [87],
- e. TPS (5) connector [88].
![](https://motoinstruction.ru/img/harley/12/118077.jpg)
Figure 4-42. Induction module electrical connectors: 1. Front fuel injector [84A]; 2. Rear fuel injector [85A]; 3. TMAP sensor [80A]; 4. IAC [87A]; 5. TPS [88A]
17. Remove prop from under rear of fuel tank. Lower rear of fuel tank into position. Install fastener, washer and nut in fuel tank rear mounting holes. Tighten to 15-20 ft·lbs (20.327.1 Nm). Install protective caps on screw ends. See 4.4 FUEL TANK: XL MODELS.
18. Install air cleaner assembly. See 4.3 AIR CLEANER ASSEMBLY.
Warning! To prevent spray of fuel, be sure quick-connect fittings are properly mated. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
19. Connect fuel hose to fuel pump module. Fill fuel tank. Carefully check for leaks around fuel pump module. See 4.4 FUEL TANK: XL MODELS.
20. Install main fuse.
21. Close left side cover.
22. Turn ignition switch to ON and OFF to reset IAC to park position.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
23. Install seat.