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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 30

HOME

3

1

f2429x8x

2

6

10

4

11

5

12

8

14

9

7

13

16

15

18

19

17

20

NOTE

Refer to Table 8-21 for

reference

number identification.

21

Figure 8-190. Wire Trough Cable Strap Locations (FLHTCU)

b. Remove and discard audio harness

2.

Thread new cable straps through slots of wire trough

where removed (cable straps 1, 2, 4, 6 and 11-17). See

Retained

Figure 8-190. Properly installed, both ends of the cable

a. Take careful note of which breakouts on the main

strap will be pointing upward.

harness interfere with removal of the audio harness.

b. Using a paint pen, draw a line on the wire bundle on

NOTE

the inboard side of the breakout conduit.

If additional clearance is needed for installation of the cable

c. Cut cable strap to release breakout from wire

staps, gently pull index pins on rear legs of wire trough from

trough.

holes in frame backbone. Slide wire trough forward to release

d. Pull on audio harness as necessary to separate

slot at bottom from T-stud on frame backbone. Reinstall wire

from the main harness.

trough after installation of the cable straps.

e. install new cable strap in slots of wire trough loosely

capturing breakout.

3.

Adjust main harness as necessary, so that the painted

f.

Move conduit on breakout so that inboard side is

lines are aligned with the cable straps installed in the

aligned with painted line.

wire trough.

g. Adjust cable strap so that it occupies the depression

4.

Place audio harness on top of main harness aligning the

or indentation left by the original cable strap and

entrance and exit markings with the openings in the wire

then tighten. Cut any excess cable strap material.

trough. Verify that the branch containing the rear head-

h. Repeat steps as necessary until audio harness can

set receptacle runs down the left leg of the wire trough,

be removed.

while the branch containing the CB antenna cable con-

nector runs down the right leg.

5.

Start tail end of each cable strap into eyelet, but do not

INSTALLATION

tighten.

6.

Route front section of audio harness forward along right

1.

Lay new and used audio harnesses side by side. Trans-

side of the steering head and then under the right side of

fer entrance and exit markings drawn on the conduit of

fairing cap to front of inner fairing.

the used harness to their approximate locations on the

new harness.

2006 Touring: Electrical

8-147

HOME

7.

See Figure 8-187. Standing at front of motorcycle, con-

nect the following connectors:

Frame

f2425x8x

Backbone

a. CB antenna cable connector [50], back of CB mod-

ule (right side).

Saddlebag

b. Audio to interconnect harness connector

[6],

6-

Guard

3

1

place Deutsch (black); top of radio (left side).

c. Radio connector [28], 35-place Amp (black); back of

radio (left side).

2

d. CB module connector

[184],

12-place Deutsch

(black); top of radio (left side).

8.

On right side of motorcycle, capture audio harness and

1

2

Captures main harness, audio harness, console pod

main harness in P-clamp. Install ground wire ring termi-

conduit and upper frame tube.

nal on screw and fasten P-clamp to right side of steering

3

Captures audio harness and upper frame tube.

head.

9.

From where the audio harness exits the wire trough on

Figure 8-191. Capture Audio Harness (FLHTCU)

outboard side of right leg, route harness rearward along

inboard side of upper frame tube (and chrome frame

tube cover), and then up the luggage rack rail to front of

9426

Tour-Pak.

10.

Pass CB antenna cable connector through hole at front

of Tour-Pak. Capture cable in grommet. Install grommet

in hole with the larger OD facing inside. See Figure 8-

188.

11.

Connect CB antenna cable connector

[50]. Capture

antenna cable in front adhesive clip inside Tour-Pak.

12.

Connect rear speaker/passenger controls connector

[41], 6-place Deutsch. Feed connector back up into right

side speaker box pressing trim ring into hole.

13.

Move to opposite side of motorcycle. Connect console

pod connector [53], 12-place Deutsch. Install connector

onto attachment clip anchored in hole at rear of battery

box. See Figure 8-189.

Figure 8-192. Capture Audio Harness (FLHTCU)

14.

From where the audio harness exits the wire trough on

outboard side of left leg, route harness rearward along

bottom of upper frame tube to rear of battery box, and

19.

Place cover over wire trough. Starting at the front and

then up through opening between rear of frame weld-

working rearward from side to side, engage catches to

ment and front of rear fender, continuing along inboard

latch cover. Verify that all latches are fully engaged.

side of upper frame tube (and chrome frame tube cover)

to luggage rack rail.

20.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

15.

Connect rear speaker/passenger controls connector

COMPLETE REMOVAL), FLHX, FLHT. For fuel injected

[42], 6-place Deutsch. Feed connector back up into left

models, see Section

9.4 FUEL TANK

(FUEL

side speaker box pressing trim ring into hole.

INJECTED), INSTALLATION

(AFTER COMPLETE

16.

Attach spring to rear headset receptacle using hole in

REMOVAL), FLHXI, FLHT/C/U/I, FLTRI.

wire jacket. Capture headset receptacle in bracket at

21.

Align barbed studs in right side cover with grommets in

bottom of left side speaker box.

frame downtubes and push firmly into place (no tools

17.

Install three new cable straps to secure audio harness to

required).

left and right upper frame tubes. See Figure

8-191.

22.

Install right side saddlebag. See Section 2.26 SADDLE-

Install two new cable straps to secure audio harness to

BAG, INSTALLATION.

luggage rack rails. See Figure 8-192. Cut any excess

cable strap material.

23.

Repeat steps 21 and 22 on left side of motorcycle.

18.

Tighten all cable straps in wire trough and cut any

24.

Install the outer fairing and windshield. See Section 2.30

excess cable strap material.

UPPER FAIRING/WINDSHIELD

(FLHX, FLHT/C/U),

OUTER FAIRING/WINDSHIELD, INSTALLATION.

8-148

2006 Touring: Electrical

HOME

CB ANTENNA CABLE (FLHTCU)

8.38

REMOVAL

f2423x8x

1.

Remove fuel tank. For carbureted models, see Section

4.7 FUEL TANK

(CARBURETED), COMPLETE

3

REMOVAL, FLHX, FLHT. For fuel injected models, see

Section

9.4 FUEL TANK (FUEL INJECTED), COM-

PLETE REMOVAL, FLHXI, FLHT/C/U/I, FLTRI.

2.

Remove right side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

3.

Gently pull side cover from frame downtubes (no tools

required).

2

4.

Remove the outer fairing and windshield. See Section

2.30 UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/

4

1

U), OUTER FAIRING/WINDSHIELD, REMOVAL.

5.

Locate CB antenna cable connector [50] at back of CB

module (right side). Rotate knurled ring in a counter-

1.

CB Antenna Cable Connector [50]

clockwise direction to disconnect. See Figure

8-193.

2.

Adhesive Clip

Carefully cut cable where it exits audio harness conduit.

3.

Grommet

4.

Tour-Pak Mounting Bolt

6.

Remove screw, ground wire ring terminal and P-clamp to

release main harness and audio harness from right side

of steering head.

Figure 8-194. Disconnect CB Antenna Cable Connector

7.

Starting at the front of the wire trough, and working rear-

ward from side to side, release catches to remove cover.

For most catches, carefully insert blade of flat tip screw-

8.

Carefully cut cable strap securing audio harness to right

driver into slot only as far as necessary to release catch.

upper frame tube. See Figure 8-195. Cut two cable

straps securing audio harness to luggage rack rail and

speaker/passenger controls conduit. See Figure 8-196.

CB Antenna

9.

Open Tour-Pak. Open map pocket and remove acorn

Cable [50]

nuts

(with flat washers). Remove map pocket and

molded liner from Tour-Pak.

10. Disconnect CB antenna cable connector [50]. Release

cable from front adhesive clip inside Tour-Pak. See Fig-

ure 8-194.

11. Pull right side grommet into Tour-Pak and remove from

CB antenna cable. Feed CB antenna cable through hole

at front of Tour-Pak.

12. Carefully cut CB antenna cable where it exits audio har-

ness conduit.

INSTALLATION

NOTE

f2356x8x

Place new CB antenna cable on motorcycle following original

path. Note that the cable follows the audio harness routed to

Figure 8-193.

Remove Outer

Fairing (FLHTCU)

the rear right side of the motorcycle.

2006 Touring: Electrical

8-149

HOME

1.

At front of inner fairing, rotate knurled ring to connect CB

antenna cable connector [50] at back of CB module

Frame

f2425x8x

Backbone

(right side). See Figure 8-193.

2.

Route free end of CB antenna cable rearward under the

Saddlebag

fairing cap to right side of the steering head.

Guard

1

3.

Capture CB antenna cable, audio harness and main har-

ness in P-clamp. Install ground wire ring terminal on

screw and fasten P-clamp to right side of steering head.

4.

Route CB antenna cable rearward through opening at

front of wire trough. Exiting wire trough through opening

on outboard side of right leg, route cable rearward along

inboard side of upper frame tube (and chrome frame

1

Captures CB antenna cable, audio harness and upper

tube cover), and then up the luggage rack rail to front of

frame tube.

Tour-Pak.

5.

Loosely install new cable strap to secure CB antenna

Figure 8-195. Capture CB Antenna Cable (FLHTCU)

cable to right upper frame tube. See Figure

8-195.

Loosely install two new cable straps to secure CB

antenna cable to luggage rack rail and speaker/passen-

9426

ger controls conduit. See Figure 8-196.

6.

Feed CB antenna cable connector through hole at front

of Tour-Pak. Capture cable in grommet. Install grommet

in hole with the larger OD facing inside. See Figure 8-

194.

3

7.

Connect CB antenna cable connector

[50]. Capture

cable in front adhesive clip inside Tour-Pak.

8.

Tighten three cable straps securing CB antenna cable to

2

upper frame tube, luggage rack rail and speaker/passen-

ger controls conduit. Cut any excess cable strap mate-

rial.

9.

Install molded liner in Tour-Pak. Install map pocket and

secure using acorn nuts (with flat washers). Close Tour-

Pak.

Figure 8-196. Capture CB Antenna Cable (FLHTCU)

10.

Place cover over wire trough. Starting at the front and

working rearward from side to side, engage catches to

12. Install the outer fairing and windshield. See Section 2.30

latch cover. Verify that all latches are fully engaged.

UPPER FAIRING/WINDSHIELD

(FLHX, FLHT/C/U),

11.

Install fuel tank. For carbureted models, see Section 4.7

OUTER FAIRING/WINDSHIELD, INSTALLATION.

FUEL TANK (CARBURETED), INSTALLATION (AFTER

13. Align barbed studs in right side cover with grommets in

COMPLETE REMOVAL), FLHX, FLHT. For fuel injected

frame downtubes and push firmly into place (no tools

models, see Section

9.4 FUEL TANK

(FUEL

required).

INJECTED), INSTALLATION

(AFTER COMPLETE

REMOVAL), FLHXI, FLHT/C/U/I, FLTRI.

14. Install right side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

8-150

2006 Touring: Electrical

HOME

SPECIFICATIONS

9.1

EFI FUSES

TORQUE VALUES

Fuel Pump

15

Blue

Blade

Item

ft/in-lbs

Nm

ECM Power

15

Blue

Blade

Battery hold-down clamp

15-20 ft-lbs

20-27 Nm

TORX screw

Battery cable bolt

60-96 in-lbs

6.8-10.9 Nm

1

ECM socket screws

50-60 in-lbs

5.7-6.8 Nm

4

Electrical bracket flange

36-48 in-lbs

4.1-5.4 Nm

nuts

3

CKP sensor screw

90-120 in-lbs

10.2-13.6 Nm

ET sensor

120-180 in-lbs

13.6-20.3 Nm

Fuel tank rear mounting

15-20 ft-lbs

20-27 Nm

2

bolt

f2223x9x

Fuel tank front mounting

15-20 ft-lbs

20-27 Nm

bolts

Fuel tank canopy TORX

18-24 in-lbs

2.0-2.7 Nm

screws

1.

EFI System Relay

3.

Fuel Pump Fuse

Fuel level sender TORX

2.

ECM Power Fuse

4.

Spare Fuse

25-35 in-lbs

2.8-4.0 Nm

screw

Fuel supply line

Figure 9-1. EFI Fuses (Under Right Side Cover)

22-26 ft-lbs

29.8-35.3 Nm

quick-connect fitting

Intake flange adapter

96-144 in-lbs

10.9-16.3 Nm

screws

Exhaust flange adapter

100-120 in-lbs

11.3-13.6 Nm

nuts

Fuel supply tube clamp hex

90-110 in-lbs

10.2-12.4 Nm

screw

IAT sensor TORX screw

15-20 in-lbs

1.7-2.3 Nm

TP sensor TORX screws

15-20 in-lbs

1.7-2.3 Nm

Throttle cable/IAC bracket

20-35 in-lbs

2.3-4.0 Nm

TORX screws

Console mounting bolt

50-90 in-lbs

5.7-10.2 Nm

acorn nut

2006 Touring: Fuel Injection

9-1

HOME

ELECTRICAL BRACKET ASSEMBLY

9.2

3.

Gently pull side cover from frame downtubes (no tools

DATA LINK CONNECTOR

required).

4.

Gently pull on data link connector [91] to disengage from

SETTING ENGINE IDLE SPEED

arms on electrical bracket. See Figure 9-2.

5.

Remove rubber protective plug from data link connector.

NOTE

6.

See DIGITAL TECHNICIAN (Part No. HD-44750) or the

Engine idle speed can only be set using DIGITAL TECHNI-

TOURING MODELS ELECTRICAL DIAGNOSTIC MAN-

CIAN (Part No. HD-44750). Do not tamper with the throttle

UAL to use the data link connector for system diagnosis

stop screw as it will not permanently change idle speed.

and electrical troubleshooting.

1.

Turn the ignition/light key switch to OFF.

7.

Install protective plug in data link connector.

2.

Remove right side saddlebag. See Section 2.26 SAD-

8.

With the plug side down and in contact with tab, position

DLEBAG, REMOVAL.

connector between arms on electrical bracket.

1

5,6

4

2

3

f2377x8x

1.

Data Link Connector [91]

2.

EFI Fuse Block (EFI System Relay, ECM

4.

ECM

Power Fuse, Fuel Pump Fuse)

5.

VSS Connector [65] (Under Bracket)

3.

ECM Connector [78]

6.

P&A Security Siren Connector [142] (Under Bracket)

Figure 9-2. Electrical Bracket Assembly

2006 Touring: Fuel Injection

9-3

HOME

2.

Engage tabs on fuse block with slots in bracket. Slide

fuse block up into cavity. Gently tug on conduit to verify

1

that fuse block is locked in place.

4

3.

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

4.

Install right side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

3

f2223x9x

ECM

2

REMOVAL

1.

EFI System Relay

3.

Fuel Pump Fuse

1.

Remove right side saddlebag. See Section 2.26 SAD-

2.

ECM Power Fuse

4.

Spare Fuse

DLEBAG, REMOVAL.

2.

Gently pull side cover from frame downtubes (no tools

Figure 9-3. EFI Fuse Block

required).

3.

Depress external latch and use rocking motion to

9.

Align barbed studs in side cover with grommets in frame

remove ECM connector [78]. See Figure 9-2.

downtubes and push firmly into place

(no tools

4.

Remove two socket screws to detach ECM from electri-

required).

cal bracket.

10.

Install right side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

INSTALLATION

1.

Align holes in ECM with those in electrical bracket.

EFI SYSTEM RELAY/EFI FUSES

Install two socket screws and tighten to 50-60 in-lbs

(5.7-6.8 Nm). See Figure 9-2.

2.

Install ECM connector

[78]. Push connector halves

REMOVAL

together until latch clicks.

1.

Remove right side saddlebag. See Section 2.26 SAD-

3.

Align barbed studs in side cover with grommets in frame

DLEBAG, REMOVAL.

downtubes and push firmly into place

(no tools

2.

Gently pull side cover from frame downtubes (no tools

required).

required).

4.

Install right side saddlebag. See Section 2.26 SADDLE-

3.

Locate painted white dot on inboard side of fuse block.

BAG, INSTALLATION.

Pressing on dot, gently tug on conduit to release tabs on

fuse block from slots in bracket.

4.

Pull relay/fuses from slots in fuse block and inspect for

damage. See Figure 9-3. Replace fuse if the element is

SECURITY SIREN CONNECTOR

burned or broken. Standard automotive type ATO fuses

are used.

NOTE

REMOVAL

While a single spare 15 amp fuse is stored in the EFI fuse

block, one extra 10 amp fuse and one extra 15 amp fuse are

1.

Remove right side saddlebag. See Section 2.26 SAD-

also located in the system fuse block cover. See Section 8.3

DLEBAG, REMOVAL.

SYSTEM FUSES for more information.

2.

Gently pull side cover from frame downtubes (no tools

required).

INSTALLATION

3.

Remove two flange nuts to release electrical bracket

1.

Install relay/fuses in slots of fuse block. See Figure 9-3.

from studs on side of battery box. See Figure 9-4.

9-4

2006 Touring: Fuel Injection

HOME

INSTALLATION

f1847x8x

1.

Install security siren connector [142] and VSS connector

[65] on inboard side of electrical bracket as shown in

Figure 9-4. Be sure that conduit and cables are properly

routed or wires may be pinched during installation.

2.

Slide electrical bracket onto studs at side of battery box.

[65]

3.

Install flange nuts on studs and tighten to 36-48 in-lbs

(4.1-5.4 Nm).

4.

Align barbed studs in side cover with grommets in frame

downtubes and push firmly into place

(no tools

required).

5.

Install right side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

ELECTRICAL BRACKET

[65] VSS

[142]

[142] P&A Security Siren

REMOVAL

Figure 9-4. Electrical Bracket (Inboard Side)

1.

Remove right side saddlebag. See Section 2.26 SAD-

DLEBAG, REMOVAL.

2.

Gently pull side cover from frame downtubes (no tools

4.

Align holes in ECM with those in electrical bracket.

required).

Install two socket screws and tighten to 50-60 in-lbs

(5.7-6.8 Nm). See Figure 9-2.

3.

Gently pull on data link connector [91] to disengage from

arms on electrical bracket. See Figure 9-2.

5.

Install ECM connector

[78]. Push connector halves

together until latch clicks.

4.

Locate painted white dot on inboard side of fuse block.

Pressing on dot, gently tug on conduit to release tabs on

6.

Engage tabs on fuse block with slots in bracket. Slide

fuse block from slots in bracket.

fuse block up into cavity. Gently tug on conduit to verify

that fuse block is locked in place.

5.

Depress external latch and use rocking motion to

remove ECM connector [78]. See Figure 9-2.

7.

With the plug side down and in contact with tab, position

data link connector

[91] between arms on electrical

6.

Remove two socket screws to detach ECM from electri-

cal bracket.

bracket.

7.

Remove two flange nuts to release electrical bracket

8.

Align barbed studs in side cover with grommets in frame

from studs on side of battery box. See Figure 9-4.

downtubes and push firmly into place

(no tools

required).

8.

Remove security siren connector [142] and VSS connec-

tor [65] from inboard side of electrical bracket.

9.

Install right side saddlebag. See Section 2.26 SADDLE-

BAG, INSTALLATION.

INSTALLATION

1.

Install security siren connector [142] and VSS connector

[65] on inboard side of electrical bracket as shown in

Figure 9-4. Be sure that conduit and cables are properly

routed or wires may be pinched during installation.

2.

Slide electrical bracket onto studs at side of battery box.

3.

Install flange nuts on studs and tighten to 36-48 in-lbs

(4.1-5.4 Nm).

2006 Touring: Fuel Injection

9-5

HOME

SENSORS

9.3

GENERAL

f2416x8x

Six sensors inform the ECM of the environmental and engine

operating factors influencing fuel and spark requirements.

The sensors are as follows:

● IAT Sensor

● TP Sensor

● MAP Sensor

● BAS (Internal to TSM/TSSM)

● CKP Sensor

● ET Sensor

[77]

[79]

IAT SENSOR

[46] Stator

[46]

See Section 9.5 INDUCTION MODULE ASSEMBLY, IAT

[77] Voltage Regulator

SENSOR.

[79] CKP Sensor

Figure 9-5. Voltage Regulator (Left Side View)

TP SENSOR

See Section 9.5 INDUCTION MODULE ASSEMBLY, TP

f2217x8x

SENSOR.

MAP SENSOR

See Section 9.5 INDUCTION MODULE ASSEMBLY, MAP

SENSOR.

BAS

See Section 8.18 TSM/TSSM.

CKP SENSOR

REMOVAL

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

Figure 9-6. Remove Sensor Mount Socket Screw

MAXI-FUSE, REMOVAL.

2.

Locate CKP sensor connector [79], 2-place Deutsch,

fixed to bracket at bottom of voltage regulator. See Fig-

ure 9-5.

5.

Remove allen head socket screw to free CKP sensor

mount from front left side of crankcase. Pull sensor from

3.

Push connector toward right side of motorcycle to disen-

bore. See Figure 9-6.

gage small end of slot on attachment clip from T-stud on

bracket. Lift connector off T-stud.

6.

Pull sensor to draw convoluted tubing and connector out

4.

Depress button on socket terminal side and pull apart

from under voltage regulator.

pin and socket halves.

9-6

2006 Touring: Fuel Injection

HOME

INSTALLATION

O-Ring

1.

Hand start threaded end of new temperature sensor into

cylinder head bore.

2.

Slide 3/4 inch deepwell socket over sensor body hex and

tighten to 120-180 in-lbs (13.6-20.3 Nm).

3.

Install ET sensor connector [90], 2-place Delphi, at back

of front cylinder.

4.

Pull boot over sensor to keep out dirt and debris.

5.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

f2321x8x

MAXI-FUSE, INSTALLATION.

Figure 9-7. CKP Sensor

Sensor

Body Hex

INSTALLATION

Thermistor

1.

Install new O-ring on sensor body if missing, distorted,

pinched or otherwise damaged. Apply a thin film of clean

H-D 20W50 engine oil to O-ring before installation.

2.

Push sensor into bore aligning hole in sensor mount with

hole in spot face. Install allen head socket screw and

tighten to 90-120 in-lbs (10.2-13.6 Nm). See Figure 9-6.

3.

Route connector and convoluted tubing under front

f1699x9x

engine stabilizer link to underside of voltage regulator.

Figure 9-8. ET Sensor

4.

Mate pin and socket halves of CKP sensor connector

[79]. See Figure 9-5.

5.

Place large end of slot on attachment clip over T-stud on

bracket. Push connector toward left side of motorcycle to

engage small end of slot.

6.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

MAXI-FUSE, INSTALLATION.

ET SENSOR

REMOVAL

1.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

MAXI-FUSE, REMOVAL.

2.

On left side of motorcycle, pull back boot at back of front

cylinder and remove ET sensor connector [90], 2-place

Delphi.

3.

Slide a 3/4 inch deepwell socket over the sensor body

hex and turn counter-clockwise to loosen. See Figure 9-

8. When sensor turns easily, pull out the deepwell socket

and remove sensor by hand.

2006 Touring: Fuel Injection

9-7

HOME

FUEL TANK (FUEL INJECTED)

9.4

manner. Gasoline is extremely flammable and highly

COMPLETE REMOVAL

explosive. Inadequate safety precautions could result in

death or serious injury.

FLHXI, FLHT/C/U/I, FLTRI

CAUTION

1WARNING

Do not kink crossover hose or crimp shut using pliers or

Gasoline is extremely flammable and highly explosive.

similar tool. Damage to the rigid inner lining will occur.

When servicing the fuel system, do not smoke or allow

1.

Drain fuel tank as follows:

open flame or sparks in the vicinity. Inadequate safety

precautions could result in death or serious injury.

Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D.

Insert bolt in one end of hose and install hose clamp to

ensure that end is securely plugged. Using a side cutters, cut

1WARNING

clamp from one end of crossover hose beneath fuel tank.

Gasoline will drain from the crossover hose when dis-

Quickly replace crossover hose on fuel tank fitting with open

connected from the fuel tank. Thoroughly wipe up any

end of short hose while directing flow of gasoline from free

spilled fuel immediately. Dispose of rags in a suitable

end of crossover hose into suitable container.

f1969x9x

1

5

2

6

7

3

4

8

1.

Canopy

5.

Fuel Filter Canister

2.

Fuel Level Sender and Float

6.

Fuel Pressure Regulator

3.

Fuel Pump

7.

Fuel Pressure Regulator to Supply Fitting Tubing

4.

Fuel Pump to Filter Canister Tubing

8.

Supply Fitting (Check Valve)

Figure 9-9. Fuel Tank Assembly (FLHXI, FLHT/C/U/I, FLTRI)

9-8

2006 Touring: Fuel Injection

HOME

NOTE

The fuel tank mounting bolts have both an internal TORX

recess and an external hex, which allows them to be

removed with either a T40 TORX bit or a 1/2 inch open end/

box wrench. Use of the external hex allows the front mount-

ing bolts to be removed without having to loosen or remove

the fairing lowers, if installed.

Fuel

Pump

6.

Open fuel door on console. Remove two Allen head

screws inboard of rubber bumpers. These screws secure

console to clip nuts on the canopy bracket. If present,

also remove Allen head screw to detach flange at rear of

console from clip nut on fuel tank weldment (absent on

FLHXI models).

7.

Lay a clean shop towel on forward part of rear fender.

f2223x9x

8.

Remove filler cap from neck of fuel tank. Remove con-

Figure 9-10. EFI Fuse Block

sole and lay upside down on shop towel. Reinstall filler

cap.

2.

Remove seat. See Section 2.25 SEAT, REMOVAL.

9.

Remove fuel level sender/fuel pump connector [141], 4-

place Packard, at top of canopy.

1WARNING

10. Gently pry fuel vapor vent tube from fitting on filler neck

The gasoline in the fuel supply line downstream of the

of fuel tank. Exercise caution to avoid pulling fitting from

fuel pump is under high pressure (58 psi). To avoid an

filler neck.

uncontrolled discharge or spray of gasoline, always

purge the system of high pressure gas before the fuel

supply line is disconnected. Gasoline is extremely flam-

1WARNING

mable and highly explosive. Inadequate safety precau-

tions could result in death or serious injury.

A small amount of gasoline may drain from the fuel sup-

ply line when disconnected from the fuel tank. Thor-

3.

Purge the fuel supply line of high pressure gas. Proceed

oughly wipe up any spilled fuel immediately. Dispose of

as follows:

rags in a suitable manner. Gasoline is extremely flamma-

a. Remove the 15 amp fuel pump fuse. See Figure 9-

ble and highly explosive. Inadequate safety precautions

10. If necessary, see Section

9.2 ELECTRICAL

could result in death or serious injury.

BRACKET ASSEMBLY, EFI SYSTEM RELAY/EFI

FUSES, REMOVAL.

f2021x9x

b. Start the engine and allow the motorcycle to run.

Fuel

Tank

c. When the engine stalls, operate starter for 3 sec-

onds to remove remaining fuel from fuel lines.

1WARNING

Chrome

To protect against shock and accidental start-up of vehi-

Sleeve

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

4.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

5.

Remove two fuel tank front mounting bolts (with flat

washers) from left and right side of frame. Remove bolt

(with flat washer) to free rear of fuel tank from frame

backbone. On FLHXI models, removal of rear bolt also

releases console bracket.

Figure 9-11. Fuel Supply Line Fitting

2006 Touring: Fuel Injection

9-9

HOME

f2378x8x

f2418x8

1

2

3

1

FLHXI

FLHRSI

2

f2379x8x

f2419x8

1

2

3

4

1

FLHT/C/U/I

FLHR/C/I

2

1.

Fuel Vapor Vent Tube (To Vapor Valve)

2.

Fuel Overflow Hose

3.

Fuel Tank Harness

1.

Fuel Vapor Vent Tube (To Vapor Valve)

(To Fuel Pump and Fuel Level Sender)

2.

Main Harness Conduit

4.

Console Pod Conduit (FLHTCUI Only)

(To Fuel Pump and Fuel Level Sender)

Figure 9-12. Console Cable/Hose Routing

Figure 9-13. Console Cable/Hose Routing

(FLHXI, FLHT/C/U/I)

(FLHR/C/S/I)

8.

Install bolt (with flat washer) to secure rear of fuel tank to

present, also install Allen head screw to fasten rear

frame backbone. On FLHXI models, capture console

flange of console to clip nut on fuel tank weldment

bracket during installation. Tighten bolt to 15-20 ft-lbs

(absent on FLHXI models). Tighten screw to 25-30 in-lbs

(2.8-3.4 Nm).

(20-27 Nm).

11. Insert bolt through battery negative cable (black) into

9.

Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

threaded hole of battery negative (-) terminal. Tighten

27 Nm).

bolt to 60-96 in-lbs (6.8-10.9 Nm).

10.

Open fuel door on console. Install two Allen head screws

12. Install the 15 amp fuel pump fuse. See Figure 9-10. If

necessary, see Section 9.2 ELECTRICAL BRACKET

to secure front of console to clip nuts on canopy bracket.

ASSEMBLY, EFI SYSTEM RELAY/EFI FUSES, INSTAL-

Alternately tighten screws to 25-30 in-lbs (2.8-3.4 Nm). If

LATION.

2006 Touring: Fuel Injection

9-11

HOME

13. Install seat. See Section 2.25 SEAT, INSTALLATION.

Convoluted

FLHR/C/S/I

Tubing

1.

Work fuel tank into position aligning front flange holes

with those in left and right side of frame.

2.

Start fuel tank front mounting bolts (with flat washers).

3.

Route free end of crossover hose under frame backbone

and in front of ignition coil to other side of fuel tank.

Install convoluted tubing, if removed, and new clamp

onto hose. Install hose onto fitting at bottom of fuel tank

(after removing temporary plug) and crimp clamp using

8870

HOSE CLAMP PLIERS (HD-97087-65B).

Figure 9-14. Fuel Gauge (FLHR/C/S)

1WARNING

Exercise caution to avoid twisting the fuel supply line fit-

12. Connect fuel gauge to main harness. Route pin housing

ting, as any cracks in the plastic construction of the line

and convoluted tubing forward and then inboard

can result in gas leaks. Gas leakage can cause fire or

between front of crossover hose fitting and bottom of fuel

explosion which could result in death or serious injury.

tank. Mate pin and socket halves of fuel gauge connec-

tor [117], 4-place Multilock. Feed connector into tunnel

4.

Locate quick-connect fitting on left side of fuel tank. Pull

of fuel tank. See Figure 9-14.

up on chrome sleeve and insert neck of fuel supply line

fitting. While pushing up on bottom of fitting, pull down

13. Insert bolt through battery negative cable (black) into

on chrome sleeve until it “clicks” into the locked position.

threaded hole of battery negative (-) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

1WARNING

14. Install the 15 amp fuel pump fuse. See Figure 9-10. If

necessary, see Section 9.2 ELECTRICAL BRACKET

To avoid an uncontrolled discharge or spray of gasoline,

ASSEMBLY, EFI SYSTEM RELAY/EFI FUSES, INSTAL-

always be sure the quick-connect fitting is properly

LATION.

mated. A slight tug on the fuel supply line fitting will ver-

ify this condition. Gasoline is extremely flammable and

15. Install seat. See Section 2.25 SEAT, INSTALLATION.

highly explosive. Inadequate safety precautions could

result in death or serious injury.

5.

Connect fuel vapor vent tube to fitting at top of canopy.

PARTIAL REMOVAL

6.

Slide head of console mounting bolt into slot at top of

canopy.

FLHXI, FLHT/C/U/I, FLTRI

7.

Moving instrument console toward installed position,

install fuel level sender/fuel pump connector [141], 4-

place Packard, at top of canopy. Bend flexible clamp to

1WARNING

capture main harness conduit.

Gasoline is extremely flammable and highly explosive.

8.

Exercising caution to avoid pinching harness and vent

When servicing the fuel system, do not smoke or allow

tube, align hole in instrument console with console

open flame or sparks in the vicinity. Inadequate safety

mounting bolt and place into position on fuel tank. See

precautions could result in death or serious injury.

Figure 9-13.

9.

Install bolt (with flat washer) to secure rear of fuel tank to

1.

Remove seat. See Section 2.25 SEAT, REMOVAL.

frame backbone. On FLHRSI models, capture instru-

ment console bracket during installation. Tighten bolt to

1WARNING

15-20 ft-lbs (20-27 Nm).

10. Tighten fuel tank front mounting bolts to 15-20 ft-lbs (20-

The gasoline in the fuel supply line downstream of the

27 Nm).

fuel pump is under high pressure (58 psi). To avoid an

uncontrolled discharge or spray of gasoline, always

11. Install acorn nut at top of instrument console and tighten

purge the system of high pressure gas before the fuel

to 50-90 in-lbs (5.7-10.2 Nm). If present, also install Phil-

supply line is disconnected. Inadequate safety precau-

lips screw and large flat washer (absent on FLHRSI

tions could result in death or serious injury.

models). Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

9-12

2006 Touring: Fuel Injection

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