![](https://motoinstruction.ru/img/harley/12/118121.jpg)
Figure 4-86. Evaporative emissions control system (typical): 1. Induction module; 2. Fuel tank (XL models only); 3. Charcoal canister; 4. External vapor valve (XL models only); 5. Fuel tank-to-vapor valve hose; 6. Vapor valve-to-canister hose; 7. Purge hose; 8. Fuel supply hose; 9. Vent fitting (XR 1200X); 10. Fuel tank (XR 1200X)
See Figure 4-86. The EVAP functions in the following manner:
- Hydrocarbon vapors in the fuel tank (2, 10) are vented through the vapor valve (4) or vent fitting (9). The vapors are stored in the charcoal canister (3). When tipped, the valve closes. Gasoline cannot leak into the charcoal canister from the vapor valve hoses (5, 6).
- When the engine is running, intake negative pressure (vacuum) slowly draws hydrocarbon vapors from the charcoal canister through the purge hose (7). These vapors pass through the intake and are burned as part of normal combustion in the engine.
Warning! Keep evaporative emissions vent lines away from exhaust and engine. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Note. The EVAP system is designed to operate with a minimum of maintenance. Check that all hoses are connected and correctly routed. They cannot be pinched, kinked, cracked or torn. Improper connections could leak charcoal from canister.
Charcoal canister
FASTENER | TORQUE VALUE | |
EVAP canister mounting bracket screw | 17-22 ft·lbs | 23.1-29.9 Nm |
Master cylinder mounting bracket, rear, screw: XL models | 17-22 ft·lbs | 23.0-29.8 Nm |
EVAP canister mounting bracket screw | 17-22 ft·lbs | 23.1-29.9 Nm |
EVAP canister clip mounting screw | 36-60 in·lbs | 4.1-6.8 Nm |
EVAP canister guard screw | 35-45 in·lbs | 4.0-5.1 Nm |
The charcoal canister is mounted to a bracket attached to the rear brake master cylinder bracket, near the bottom of the frame in front of the rear fork pivot point.
Removal
1. See Figure 4-87. Remove two screws (1) and canister guard (2).
![](https://motoinstruction.ru/img/harley/12/118122.jpg)
Figure 4-87. Charcoal canister mounting (typical): 1. Screw (2); 2. Canister guard; 3. Canister mounting bracket; 4. Screw (2); 5. Canister clip; 6. Charcoal canister; 7. Screw (2); 8. Washer (2); 9. Purge hose from induction module; 10. Vent hose from vapor valve; 11. Rear master cylinder bracket; 12. Rear master cylinder; 13. Screw (2); 14. Washer (2)
2. Mark the two hoses (9, 10) connected to charcoal canister (6). Disconnect hoses from canister.
3. Press the locking tabs at the left end of canister clip (5). Slide canister towards left side of vehicle until it disengages from canister clip.
4. Remove two screws (7) and washers (8) to detach canister clip from canister mounting bracket (3).
5. XL Models: If canister mounting bracket requires repair/replacement, proceed as follows:
- a. Remove two screws (13) and washers (14) securing rear master cylinder to mounting bracket. This will allow you to move the rear master cylinder to access the remaining fasteners.
- b. Remove two screws (4) to detach canister mounting bracket from rear master cylinder mounting bracket.
6. XR 1200X: See Figure 4-88. If canister mounting bracket requires repair/replacement, remove two screws (2) to detach canister mounting bracket from frame.
![](https://motoinstruction.ru/img/harley/12/118123.jpg)
Figure 4-88. Charcoal canister mount: XR 1200X: 1. Screw; 2. Canister mounting bracket screws (2); 3. Canister mounting bracket; 4. Fuel tank-to-canister hose; 5. Canister-to-induction module hose
Note. It is not necessary to remove brake line clamp screw (1).
Installation
Note. XL Models: Verify that the EVAP canister mounting hardware does not contact the rear stabilizer ground strap.
1. XL Models: See Figure 4-87. If canister mounting bracket (3) was removed, proceed as follows:
- a. Attach bracket (3) to rear master cylinder mounting bracket and frame with two screws (4). Tighten to 1722 ft·lbs (23.1-29.9 Nm).
- b. Apply one or two drops of LOCTITE 243 to screws (13). Install rear master cylinder (12) to mounting bracket (11) with screws and washers (14). Tighten to 17-22 ft·lbs (23.0-29.8 Nm).
2. XR 1200X: See Figure 4-88. If canister mounting bracket (3) was removed, proceed as follows:
- a. Apply LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue) to the threads of the mounting screws (2).
- b. Install bracket and tighten screws (2) to 17-22 ft·lbs (23.1-29.9 Nm).
3. See Figure 4-87. Attach canister clip (5) to canister mounting bracket with two screws (7) and two washers (8). Tighten to 36-60 in·lbs (4.1-6.8 Nm).
4. Starting at left side of canister clip, slide charcoal canister (6) to the right until tabs on canister clip lock canister in place. Bend tabs outward somewhat if canister is not held securely.
5. See Figure 4-89. Connect two hoses (1,2), marked during disassembly, to their proper fittings on canister.
![](https://motoinstruction.ru/img/harley/12/118124.jpg)
Figure 4-89. Charcoal canister connections: 1. Purge hose from induction module; 2. Vent hose from fuel tank and vapor valve; 3. Clean air port (no hose connection)
6. See Figure 4-87. Install canister guard (2) using two screws (1). Tighten to 35-45 in·lbs (4.0-5.1 Nm).
Vapor valve: XL models
Removal
Notes:
- XL Models: The vapor valve is located under the left side cover in a clip molded into the ECM caddy.
- XR 1200X: The vapor valve is incorporated in the fuel tank filler housing. See 4.5 FUEL TANK: XR 1200X.
1. Open left side cover. See 2.18 LEFT SIDE COVER.
2. See Figure 4-90. Carefully remove vapor valve (2).
![](https://motoinstruction.ru/img/harley/12/118125.jpg)
Figure 4-90. Vapor valve and hose routing: XL EVAP models: 1. Fuel tank-to-vapor valve hose; 2. Vapor valve; 3. Vapor-valve-to-canister hose; 4. Vapor valve clip; 5. Fuel pump harness; 6. ECM caddy; 7. To fuel tank; 8. To charcoal canister
3. Mark two hoses (1, 3) connected to upper and lower fittings of vapor valve. Remove hoses from fittings.
Note. On non-EVAP system models, charcoal canister is absent and bottom hose of vapor valve is vented to the atmosphere.
Installation
Warning! Keep vent and vapor valve lines away from exhaust and engine. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Note. Mount the vapor valve in an upright position with the longer fitting positioned at the top or excessive fuel vapor pressure may build up within the fuel tank. Mounting the vapor valve upside down will result in fuel flow problems.
1. See Figure 4-90. Hold vapor valve (2) in an upright position with the long necked end pointing up. Insert top fitting of vapor valve into fuel tank-to-vapor valve hose (1). Install bottom vapor valve fitting into vapor valve-to-canister hose (3).
2. Carefully push body of vapor valve into clip (4) molded into the ECM caddy (6).
Note. Do NOT force vapor valve into clip. Forcing valve in to clip could cause clip to break, necessitating replacement of the ECM caddy.
3. Close left side cover.
Hose routing
Induction module
XL Models: Remove the fuel tank and air cleaner/backplate assembly to access the induction module.
XR 1200X: See Figure 4-91. Route the evaporative emissions control hose to the purge hose fitting (2) on the induction module (1).
![](https://motoinstruction.ru/img/harley/12/118126.jpg)
Figure 4-91. Emissions hose routing at induction module: 1. Induction module; 2. Purge hose (to canister) fitting
Canister hose routings: XL models
1. See Figure 4-92. Connect the vapor valve-to-canister hose (1) to the canister lower fitting marked TANK and the canister-to-induction module purge hose (2) to the upper fitting labeled CARB.
![](https://motoinstruction.ru/img/harley/12/118127.jpg)
Figure 4-92. EVAP canister and hose routing: 1. Tank to vapor valve; 2. CARB to induction module
2. Route the vapor valve-to-canister hose:
- a. Under the frame.
- b. Behind the rear brake master cylinder bracket.
- c. Up the frame tube in front of the rear fork pivot.
- d. Inside the electrical caddy to the vapor valve inside the left side cover.
3. Connect the vapor valve-to-canister hose to the vapor valve.
4. Connect fuel tank-to-vapor valve hose the the vapor valve.
5. Route the fuel tank-to-vapor valve hose forward along the left side of frame backbone and connect to fitting on bottom of fuel tank.
6. Route the canister-to-induction module purge hose:
- a. Loop behind the brake fluid lines and around the master cylinder.
- b. Behind the frame.
- c. Between the rear fork and the rear fork pivot.
- d. Behind the oil lines and up behind the oil tank.
- e. Route canister-to-induction module purge hose up right side of frame rear downtube.
- f. Loop the hose over the wire harness caddy and forward along the caddy and the frame backbone.
- g. Connect the hose to the induction module.
Note. Position the hose against the engine sub-harness and as far from the rear rocker cover as possible.
7. See Figure 4-93. Secure the hose to the holes in the wire harness caddy with barbed cable straps.
![](https://motoinstruction.ru/img/harley/12/118128.jpg)
Figure 4-93. Cable strap locations
Canister hose routings: XR 1200X
1. See Figure 4-94. Route both hoses up past canister mount and between rear fork pivot point and rear end of crankcase as shown.
![](https://motoinstruction.ru/img/harley/12/118129.jpg)
Figure 4-94. Charcoal canister mount: XR 1200X: 1. Screw; 2. Canister mounting bracket screws (2); 3. Canister mounting bracket; 4. Fuel tank-to-canister hose; 5. Canister-to-induction module hose
2. See Figure 4-95. Route fuel vapor hose (4) up along left side of frame rear downtube and outside the left electrical caddy. Connect to vapor tube (2).
![](https://motoinstruction.ru/img/harley/12/118130.jpg)
Figure 4-95. Vapor hose routing: 1. Vapor fitting; 2. Vapor tube; 3. Clamp; 4. Vapor hose
3. Connect vapor tube (2) to fitting (1) on fuel tank filler housing and place in channel on top of fuel tank.
4. Secure to electrical caddy with barbed clamp (3).
5. See Figure 4-96. Route canister-to-induction module purge hose (1) up right side of frame rear downtube. Continue routing hose forward along right side of frame backbone tube and down, connecting hose to induction module fitting (3).
![](https://motoinstruction.ru/img/harley/12/118131.jpg)
Figure 4-96. Purge hose routing: 1. Purge hose; 2. Clamp; 3. Induction module fitting; 4. Right wire harness caddy
6. Secure hose to channels on rear end of right wire harness caddy (4). Verify that hose is positioned up against engine sub-harness. Secure hose and harness with clamp (2).
7. Connect hoses to labeled fittings on left side of charcoal canister.