FUEL PUMP/FUEL GAUGE SENDING UNIT 4.14

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1 FUEL PUMP/FUEL GAUGE SENDING UNIT 4.4 GENERAL s0660x8xx Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (0000a) Refer to the Softail Models Electrical Diagnostic Manual for information on the function and testing of the fuel pump. Figure 4-6. Fuel Pump Fuse: View From Top REMOVAL. Remove seat. 756 To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (0075a). Purge the fuel supply line of high pressure gasoline. a. See Figure 4-6. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for seconds to remove any remaining fuel from the fuel lines. Figure 4-7. Acorn Nut And Washer: All But FXSTD To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a). Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-7. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.6 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. 007 Softail: Fuel System 4-7

2 760 Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0059a) 6. Drain fuel tank. a. Obtain a short section of hose (5/6 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-8. Cut clamp () from one end of crossover hose (). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-9. Unplug fuel pump module connector () [86]. 8. Remove top plate screws () and discard. 9. See Figure Pull top plate () out of fuel tank enough to expose fuel hose and clamp (). Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure.. Clamp. Crossover hose 56 Figure 4-8. Crossover Hose 0. Cut clamp and remove hose from regulator housing fitting. Exercise care to avoid bending float rod of fuel level sender. A bent float rod will result in erroneous gauge readings.. See Figure 4-4. Reach into fuel tank and push fuel pump housing (6) to disengage it from end cap (4).. See Figure 4-4. Pull fuel pump out of fuel tank enough to gain access to fuel gauge sending unit on right side of fuel tank.. See Figure 4-4. Pull tab (9) towards top of fuel tank to release fuel gauge sending unit (0) from mounting tabs. 4. Remove top plate, fuel pump and fuel gauge sending unit from fuel tank.. Top plate. Fasteners (0). Fuel pump module connector [86] 8408 Figure 4-9. Top Plate Fasteners. Clamp. Top plate Figure Fuel Line Clamp Softail: Fuel System

3 s064x8x Bail. Fuel filter. Regulator housing 4. Regulator 5. Sealing 8-4 in-lbs (.0-.7 Nm) 6. Top plate: all but FXSTDI 7. Fuel pump module connector 8. Top plate gasket 9. Top plate: FXSTDI 0. Hose. Clamp. Wire assembly. Rubber sleeve 4. End cap 5. Spring 6. Fuel pump housing 7. Rubber spacer 8. Float 9. Tab 0. Fuel level sender. Rubber cushion. Fuel pump. Cable strap 4. Cable strap 5. Fuel pump inlet filter 6. Bail bracket Figure 4-4. Fuel Pump/Fuel Gauge Sending Unit 007 Softail: Fuel System 4-9

4 DISASSEMBLY/ASSEMBLY 8409 Fuel Filter. See Figure 4-4. Disengage bail () from bail bracket (8).. See Figure 4-4. Remove bail bracket from top plate.. See Figure Remove fuel filter () from regulator housing (). 4. Cut hose clamp () and remove hose (4) from fuel filter. Exercise caution to avoid cutting or damaging hose. Discard fuel filter. Do not replace the special teflon coated fuel pump wiring with ordinary bulk wire. Ordinary insulation materials may deteriorate when in contact with gasoline. 5. Slide new hose clamp onto free end of hose (from fuel pump). Install hose onto inlet port at side of fuel filter. If necessary, use a little denatured alcohol or glass cleaner to aid installation. Crimp clamp. 6. See Figure Insert filter into fuel pressure regulator housing, so that inlet port is on fuel pump side. 7. See Figure 4-4. Slide tab on bail bracket into slot of top plate until bump on bracket engages depression at side of filter. 8. Rotate bail over bail bracket until it fully engages slots on bracket. Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even a small hole can cause a reduction in fuel pressure. Regulator. Remove fuel pump from regulator housing. See Fuel Filter under DISASSEMBLY/ASSEMBLY.. See Figure Slide fuel pressure regulator assembly forward to free arms from top plate.. Pull regulator from regulator housing by using rocking motion. 4. See Figure Apply a thin coat of clean engine oil to new regulator O-rings. 5. Install fuel pressure regulator into housing. 6. Fit fuel pressure regulator assembly into top plate. 7. Install fuel filter. See Fuel Filter under DISASSEMBLY/ ASSEMBLY. s055x9x Figure 4-4. Fuel Pump Removal Figure 4-4. Bail Bracket Softail: Fuel System

5 Fuel Pump. See Figure 4-4. Cut clamp () holding hose (0) to fuel pump ().. Disconnect fuel pump connector.. Release end of spring (5) from hook on fuel pump housing. s055x9x Be absolutely certain fuel pump is faulty before removing hinge from support arm. Hinge is damaged during removal and requires replacement of the fuel pump and bracket assembly. 4. See Figure Insert flat tip screwdriver and carefully crack plastic webbing at top of end cap. Remove end cap from top plate arm. Discard fuel pump and bracket assembly. 4 Do not replace the special teflon coated fuel pump wiring with ordinary bulk wire. Ordinary insulation materials may deteriorate when in contact with gasoline. 5. See Figure 4-4. Inspect fuel pump wiring, () replace if damaged. 6. Install new end cap on top plate arm. Make sure tab engages end cap. 7. Install spring on fuel pump housing hook. 8. Align two holes in fuel level sender with threaded hole and post on fuel pump housing. Attach fuel level sending unit to fuel pump housing. Tighten screw to 5-45 in-lbs (.8-5. Nm). 9. Connect fuel pump wiring. 0. Install new clamp over fuel pump hose and attach to new fuel pump using side of HOSE CLAMP PLIERS (Part No. HD-47).. Regulator housing. Fuel filter. Clamp 4. Hose s0554x9x Figure Fuel Filter Figure Regulator Housing f9x9x. Regulator housing. Regulator. O-rings Figure Fuel Pressure and Housing 007 Softail: Fuel System 4-

6 Fuel Level Sending Unit Wire Harness 899 Do not replace the special teflon coated fuel pump/fuel level sender wiring with ordinary bulk wire. Ordinary insulation materials may deteriorate when in contact with gasoline. Damaged fuel pump and/or fuel level sender wiring requires replacement of the fuel level sender unit.. Remove fuel pump/fuel gauge sending unit from fuel tank. See REMOVAL in this section.. Disconnect fuel pump connector.. See Figure While pushing tab () in direction shown, pull top plate connector () from top plate. 4. Discard fuel level sending unit and wiring harness. 5. Obtain new fuel level sending unit and wiring harness. 6. Install fuel level sending unit. See INSTALLATION in this section. 7. Connect top plate connector. 8. Install fuel pump connector on fuel pump. 9. Install fuel pump into fuel tank. See INSTALLATION in this section. 56 Figure End Cap Removal. Connector [86]. Tab Figure Top Plate Connector Softail: Fuel System

7 Fuel Supply Check Valve/Tube s0556x9x The in-tank check valve is housed in the quick-connect fitting. The check valve prevents the fuel tank from draining when the external supply line is disconnected.. Remove fuel pump/fuel gauge sending unit from fuel tank. See REMOVAL in this section. Gasoline can drain from the fuel line when disconnected from fuel tank. Gasoline is extremely flammable and injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0060a) Do not twist fuel line fitting, as fuel line can crack causing a fuel leak. Gasoline is extremely flammable and injury. (0074a). See Figure Pull up on chrome sleeve of quick-connect fitting () and pull down on fuel supply line fitting to disconnect. Gasoline can drain from quick-connect fitting when removing fuel line. Gasoline is extremely flammable and injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0067a). Unthread fitting from fuel tank. Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even a small hole can cause a reduction in fuel pressure.. Quick-connect fitting. Convoluted tube. O-ring Figure Quick-Connect Fitting 4. Apply a thin film of engine oil to new O-ring (). Slide O- ring down convoluted tube () until contact is made with hex on new quick-connect fitting. 5. Feed convoluted tube through hole at bottom of fuel tank. Secure fitting to fuel tank. Tighten fitting to 8 ft-lbs (4.4 Nm). 6. Pull up on chrome sleeve of quick-connect fitting and insert neck of fuel supply line fitting. While pushing up on bottom of fitting, pull down on chrome sleeve until it clicks into the locked position. To prevent spray of fuel, be sure quick-connect fittings are properly mated. Gasoline is extremely flammable and injury. (0068a) 007 Softail: Fuel System 4-

8 INSTALLATION s0550x9x Exercise care to avoid bending float rod of fuel level sender. A bent float rod will result in erroneous gauge readings. Fuel pump sits in left side of fuel tank. Fuel gauge sending unit sits in right side of fuel tank. Do not apply any type of sealant to gasket.. Install new gasket under top plate.. Install fuel gauge sender into mounting tabs. Push down on sender until it is seated in tabs.. See Figure 4-4. Install fuel pump until rubber spacer rests on bottom of fuel tank. 4. Install hose and new fuel line clamp on fuel filter fitting. 5. See Figure Pivot top plate and push down so end cap () engages fuel pump housing (). 6. See Figure 4-5. Place gasket and top plate on tank. loosely install new sealing screws. 7. Using the pattern shown, tighten T0 TORX screws to 8-4 in-lbs (.0-.7 Nm). 8. See Figure 4-9. Connect fuel pump module connector () [86]. 9. Connect console wiring and install console. 0. See Figure 4-8. Connect crossover hose () with new clamps ().. See Figure 4-6. Install the fuel pump fuse in the main wiring harness.. Connect negative battery cable.. Fill tank with gasoline and check for leaks. 4. Check fuel system pressure. See 4.5 FUEL PRES- SURE TEST. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. Install seat.. End cap. Fuel pump housing Figure End Cap Engaged 0 Figure 4-5. Top Plate Torque Sequence Softail: Fuel System

9 FUEL PRESSURE TEST 4.5 GENERAL The fuel pump delivers fuel to the fuel line, to a cavity in the induction module that supplies the fuel injectors and to the pressure regulator, where the system pressure is controlled. Excess fuel pressure is bypassed to the fuel tank through the pressure regulator. See Figure 4-5. The fuel pump fuse is located under the seat. The fuel pump can be turned on by applying battery voltage to the fuel pump fuse. Improper fuel system pressure may contribute to one of the following conditions: Cranks, but won t run. Cuts out (may feel like ignition problem). Hesitation, loss of power or poor fuel economy. Refer to the Softail Models Electrical Diagnostic Manual for further information on the function and testing of the fuel system. TESTING The fuel pressure gauge (0-00 PSI) allows for fuel injector and fuel system pressure diagnosis. A special adapter allows the gauge to be attached to the external fuel supply line. Be sure to avoid crimping of fuel line when installing/ removing fuel pressure gauge and adapter. PART NO. HD-48. Remove seat. SPECIALTY TOOL Fuel pressure gauge HD-4406 Fuel pressure gauge adapters () To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (0075a). Purge the fuel supply line of high pressure gas. a. See Figure 4-5. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for seconds to remove any remaining fuel from the fuel lines. s0660x8xx Figure 4-5. Fuel Pump Fuse: View From Top Gasoline can drain from quick-connect fitting when removing fuel line. Gasoline is extremely flammable and injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0067a). Pull up on chrome sleeve of quick-connect fitting (fitting on left side of fuel tank) and pull down on fuel supply line to disconnect. The next step requires two fuel pressure gauge adapters. Failure to use two adapters will cause the fuel line to twist. This may result in a broken fuel line or fuel line fitting. 4. Attach fuel line to gauge assembly. a. See Figure 4-5. Install a second adapter in series with the first. b. See Figure Pull up on chrome sleeve of quickconnect fitting and insert neck of FUEL PRESSURE GAUGE ADAPTER (Part No. HD-4406) into fuel supply line. c. While pushing up on bottom of adapter, pull down on chrome sleeve until it clicks into the locked position. Tug on adapter to be sure that it will not come free. d. See Figure In the same manner, install neck of second fuel supply line fitting into quick-connect fitting on fuel tank. Tug on fuel supply line to be sure that it will not come free. 007 Softail: Fuel System 4-5

10 78 To prevent spray of fuel, be sure quick-connect fittings are properly mated. Gasoline is extremely flammable and injury. (0068a) 5. Verify that the fuel valve and air bleed petcock on the FUEL PRESSURE GAUGE (Part No. HD-48) are closed. 6. See Figure 4-5. Remove protective cap from free end of fuel pressure gauge adapter. Connect fuel pressure gauge to Schroeder valve. 7. See Figure 4-5. Install fuel pump fuse. 8. Start and idle engine to pressurize the fuel system. Open the fuel valve to allow the flow of fuel down the hose of the pressure gauge. 9. Position the clear air bleed tube in a suitable container and open and close the air bleed petcock to purge the gauge and hose of air. Repeat this step several times until only solid fuel (without bubbles) flows from the air bleed tube. Close the petcock. 0. Open and close throttle to change engine speed. Note the reading of the pressure gauge. Fuel pressure should remain steady at 55-6 psi (80-45 kpa). If fuel pressure gauge reading is not within specifications, see Softail Models Electrical Diagnostic Manual for further diagnosis.. Turn the engine off. Position the air bleed tube in a suitable container. Open the air bleed petcock to relieve the fuel system pressure and purge the pressure gauge of gasoline. Gasoline can drain from the adapter when gauge is removed. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0054a). Remove fuel pressure gauge from the adapter. Install protective cap over Schroeder valve. 78 Figure 4-5. Fuel Pressure Gauge Adapters. Fuel supply line. Adapter to fuel line. Adapter to fuel tank 4. Pressure adapter/schroeder valve union 5. Fuel valve (closed position) Figure Fuel Line 5 Figure Fuel Pressure Gauge Installed Softail: Fuel System

11 Gasoline can drain from the fuel line and adapter when removed. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (0055a). Pull up on sleeve of quick-connect fitting and remove fuel supply line from fuel pressure gauge adapter. Release adapter from fuel tank in the same manner. To prevent spray of fuel, be sure quick-connect fittings are properly mated. Gasoline is extremely flammable and injury. (0068a). 4. Pull up on chrome sleeve of quick-connect fitting (forward fitting on left side of tank) and insert neck of fuel supply line fitting. While pushing up on bottom of fuel supply line fitting, pull down on chrome sleeve until it clicks into the locked position. Tug on fuel supply line to be sure that it will not come free. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. Install seat. 007 Softail: Fuel System 4-7

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