| PART NO. | SPECIALTY TOOL |
| HD-45324 | Fuel cap remover/installer |
2. See Figure 4-6. Insert fuel pump/filters/fuel level sender assembly into fuel tank. The two side by side tabs (1) on the right underside of the top plate mate to a notch in the collar in the fuel tank allowing the top plate to fall into position and the rubber spacer/bumper (5) on the bottom of the fuel pump/filters/fuel level sender assembly to rest on the bottom of fuel tank.
Figure 4-6. Fuel pump/filters/fuel level sender assembly: 1. Mating tabs to fuel tank notch; 2. Quad-seal; 3. Rheostatic slide and fuel level sender float; 4. Crossover tube; 5. Rubber spacer/bumper
3. See Figure 4-3. Orient the pointer (6) on the lock ring to point 90 degrees to the left side of the motorcycle. In this position the start of the lock ring threads match the start of the threads on the collar of the opening in the fuel tank. Thread on lock ring. Use FUEL CAP REMOVER/ INSTALLER (HD-45324) to tighten the lock ring to 54-61 Nm (40-45 ft-lbs).
4. Connect the fuel module connector (5) while supporting the top plate connector with the opposite hand.
Note. To avoid bending the connector pins, gently press the socket fuel module connector parallel or straight into the pin fuel module connector on the fuel tank top plate.
5. Install the smaller return fuel line (4) and the larger pressure fuel line (3) while supporting the mating port. Press the lines on until the click is heard that indicates engagement.
Warning! Connecting the fuel lines to the wrong outlet port can result in a reverse flow of gasoline upon start up. Inadequate safety precautions could result in death or injury.
6. Attach the pressure (3) and the return (4) fuel lines to the fuel rail.
7. Press on the fuel vapor vent hose (2) while supporting the mating port.
8. Replace fuel filler boot. Fuel as required and replace the fuel cap.
Warning! 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.
9. Connect negative battery cable.
10. Install airbox. See 1.4 Airbox and air filter.
11. Close and latch seat.
12. Replace the maxi-fuse and right side cover.
13. Check fuel system pressure. See 9.10 Fuel pressure test.