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Engine fuel supply system of motorcycle Harley V-Rod VRSCA (2002-2006)

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Fuel system specifications
Table 4-1. Capacities FUELTANK CAPACITYGALLONSLITERSTotal3.714 Torque values ITEMTORQUEFuel plate lock ring54-61 Nm40-45 ft·lbsFuel tank bracket bolts61-75 Nm45-55 ft·lbsPurge solenoid bolt6-10 Nm53-88 in·lbsMudflap stud plate fasteners8-12 Nm71-106...

Fuel pump, filters, fuel level sender assembly — removal
PART NO.SPECIALTY TOOLHD-45324Fuel cap remover/installer 1. Unlatch and open seat. Remove fuel cap, remove fuel filler boot, and replace fuel cap. Warning! Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling...

Fuel pump, filters, fuel level sender assembly — installation
1. Apply a small dab of silicone gasket sealer at four spots around the bottom side of a new quad seal. Install the quad seal onto shoulder of the tank opening. Let the gasket sealer cure for five minutes. PART NO.SPECIALTY TOOLHD-45324Fuel cap...

Suction side fuel filter
Warning! Some gasoline will drain from the individual components when disconnected from the fuel pump/filters/fuel level sender assembly. Thoroughly wipe up any spilled fuel immediately. Dispose of rags in a suitable manner. Gasoline is extremely...

Pressure side fuel filter — removal and installation
See Figure 4-5. The pressure side filter (2) filters the fuel before it inters the pressure fuel line. The pressure side filter is serviced at a service interval of 161,000 kilometers (100,000 miles) or at anytime the fuel pump is serviced. Figure...

Fuel pump — removal and installation
General The fuel pump pumps fuel from the tank sump and provides filtered, pressurized fuel to the fuel rail. The fuel rail pressure is controlled by a pressure regulator. The injectors receive fuel directly from the fuel rail. The bypass fuel from...

Fuel level sender — removal and installation
Warning! Some gasoline will drain from the individual components when disconnected from the fuel pump/filters/fuel level sender assembly. Thoroughly wipe up any spilled fuel immediately. Dispose of rags in a suitable manner. Gasoline is extremely...

Fuel tank — removal
1. Purge the fuel supply line of high pressure gasoline. a. Disconnect the fuel module connector from the top plate. See 4.2 Fuel pump/filters/fuel level sender assembly. b. Start the engine and allow the vehicle to run. When the engine stalls,...

Fuel tank — cleaning and inspecting
1. Drain the fuel tank. Use a common pump or siphon and an approved gasoline storage container of sufficient capacity. 2. Remove fuel pump/filter/fuel level sender assembly from tank. 3. Clean the tank interior with commercial cleaning solvent or a...

Fuel tank — installation
1. Position the fuel tank in the frame and position the fuel tank mounting bracket to the frame. 2. See Figure 4-7. Loosely thread in the two mounting bolts (1) and washers (2) through the forward lower slot ends (4) of the bracket into the threaded...

Vapor valve — replacement
General See Figure 4-8. The vapor valve is mounted to the left hand frame rail directly in front of the fuel tank. Hydrocarbon vapors in the fuel tank are vented through a hose to the vapor valve. If the vehicle is tipped at an abnormal angle, the...

Evaporative emissions control — California models
General Harley-Davidson motorcycles sold in the state of California are equipped with an evaporative (EVAP) emissions control system. The EVAP system prevents fuel hydrocarbon vapors from escaping into the atmosphere and is designed to meet the...

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