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 California Air Resource Board (CARB) regulations in effect at the time of manufacture.
The EVAP functions in the following manner:
- Hydrocarbon vapors in the fuel tank are directed through the vapor valve and stored in the charcoal canister. If the vehicle is tipped at an abnormal angle, the vapor valve closes to prevent liquid gasoline from leaking out of the fuel tank through the vent hose.
- When the engine is running, intake venturi negative pressure (vacuum) draws off the hydrocarbon vapors from the charcoal canister when the purge solenoid is open. These vapors pass through the intake and are burned as part of normal combustion in the engine. The purge solenoid is timed to the throttle position but is disabled at startup, low engine temperature, low engine speed, or low vehicle speed.
Warning! Verify that the evaporative emissions vent hoses do not contact hot exhaust or engine parts. The hoses contain flammable vapors that can be ignited if damaged which could result in death or serious injury.
Note. The EVAP system has been designed to operate with a minimum of maintenance. Check that all hoses are properly connected, are not pinched or kinked and are routed properly Improper connections could leak charcoal from canister.
![](https://motoinstruction.ru/img/harley/2/111175.jpg)
Figure 4-10. Evaporative emissions control system: 1. Fuel tank top plate; 2. Vent hose; 3. Purge solenoid; 4. Purge solenoid to throttle body hose; 5. Canister to purge solenoid hose; 6. Vapor valve frame clip; 7. Charcoal canister; 8. Vapor valve
Purge solenoid
The purge solenoid allows hydrocarbon vapor flow from the charcoal canister to the throttle body. The purge solenoid is timed to the throttle position but is disabled at startup, low engine temperature, low engine speed, or low vehicle speed. The power for the solenoid comes from the system relay. The EVMS provides the path to ground to trigger the purge solenoid.
Note. Before removing the purge solenoid, perform diagnostics listed in the VRSCA Electrical Diagnostic Manual (Part No. 99499-02).
![](https://motoinstruction.ru/img/harley/2/111176.jpg)
Figure 4-11. Purge solenoid (mudflap removed)
Removal
1. Remove right side cover.
Warning! To avoid accidental start-up of vehicle and possible personal injury, remove the maxi-fuse before proceeding. Inadequate safety precautions could result in death or serious injury.
2. See Figure 4-2. Remove maxi-fuse.
3. Remove the two hex-nuts fastening the mud flap stud plate and the mudflap to the frame fender weldment. Remove the mudflap and the stud plate. See 2.36 Rear fender/supports.
4. Disconnect the wire connector to the purge solenoid.
5. Gently pull off the charcoal canister to purge solenoid hose.
6. Gently pull off the purge solenoid to throttle body hose.
7. Remove the hold down bolt and the purge solenoid.
Installation
1. Thread the purge solenoid bolt into the threaded fender skin weldment boss and tighten it into the purge solenoid under the fender skin. Tighten to 6-10 Nm (53-88 in-lbs).
2. Push on the purge solenoid to throttle body hose.
3. Push on the charcoal canister to purge solenoid hose.
4. Connect the wire connector.
5. Install the mudflap and stud plate to the frame fender weldment. Thread on and tighten the two hex-nuts to 8-12 Nm (71-106 in-lbs). See 2.36 Rear fender/supports.
6. Replace the maxi-fuse and the right side cover.
Note. On non-California models the wire connector to the purge solenoid is capped with a resistive plug. However, the diagnostic codes will be the same. See Resistive plug in 4.4 Vapor valve.
Vapor valve
Warning! The vapor valve must be mounted in a vertical position, with the long fitting at the top, otherwise, excessive fuel vapor pressure may build up in the fuel tank. Excessive pressure could cause a fuel leak resulting in a fire or an explosion which could result in death or serious injury.
See Figure 4-8. The vapor valve is mounted to the left hand frame rail directly in front of the fuel tank. See 4.4 Vapor valve.
Note. On CA (California) models, the hose from the vapor valve bottom fitting goes to the charcoal EVAP canister.
Charcoal canister
Removal/lnspection
The EVAP charcoal canister is mounted below the swingarm pivot in front of the fuel tank on the shield. It can be accessed from the left side of the motorcycle.
1. See Figure 4-12. Note the two hose connections, CARB (1) and TANK (2), on the left side of the canister. Gently pull the hoses off the charcoal canister.
![](https://motoinstruction.ru/img/harley/2/111177.jpg)
Figure 4-12. Charcoal canister connections: 1. Purge hose to canister (CARB); 2. Vent hose from vapor valve and fuel tank (TANK)
2. See Figure 4-13. With a screwdriver, press the retention tang (3) in on the bottom of the canister bracket while pressing on the opposite side of the canister. When the bracket on the canister slides just far enough out of the bracket clips (1) to hold the bottom tang in, press in on the top tang (2) and continue to slide the charcoal canister out until it drops free from the bracket clips.
![](https://motoinstruction.ru/img/harley/2/111178.jpg)
Figure 4-13. Charcoal canister mounting bracket: 1. Bracket clips; 2. Top retention tang; 3. Bottom retention tang
3. Remove charcoal canister.
4. Inspect and replace as required the hose sections to vapor valve.
5. Inspect and replace as required the charcoal canister to purge solenoid hose segments.
Installation
1. Position the two segments of the brackets on the new charcoal canister between the two segments of the canister mounting bracket welded to the frame.
2. See Figure 4-13. Press the canister in toward the bracket until it holds both the upper and lower retention tangs in.
3. Slide the canister into the bracket clips (1) until the tangs (2, 3) snap into place.
4. See Figure 4-12. Attach hoses to left side canister connections (1,2) as marked.
5. Install new EVAP system label on front frame down tube.
Hose routing/replacement
Note. Record location of cable ties before removal. Install cable ties in same location when installing.
Warning! Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or serious injury.
1. Route purge solenoid hoses.
- a. See Figure 4-10. Attach the purge solenoid to throttle body hose (4) to the throttle body.
- b. Route purge solenoid to throttle body hose (4) under frame tube to purge solenoid (3). Install cable ties.
- c. Attach the canister to purge solenoid hose (5) to the purge solenoid.
- d. Route canister to purge solenoid hose (5) to the charcoal canister (7). See Figure 4-12. Attach the hose to the fitting marked CARB (1) on left side of canister. Install cable ties.
2. Route fuel tank vapor vent hoses.
- a. See Figure 4-10. Route fuel tank vent hose (2) along left side of frame to top or long end of the vapor valve (8) clipped on frame tube. Install cable ties. Gently press the hose onto the top plate outlet port and onto the long end of the vapor valve.
- b. See Figure 4-12. Attach short segment of hose to the bottom or short end of the vapor valve and to the fitting marked TANK (2) on left side of the charcoal canister.