harley fuel injector removal

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2003 SUZUKI SV 650 FUEL SYSTEM AND THROTTLE BODY SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)

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2007 Softail HARLEY DAVIDSON FUEL PUMP/ FUEL GAUGE SENDING UNIT REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-03-2012

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1. Remove seat. 1 WARNING 1 WARNING 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. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. 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 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. 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. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). 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 4-39. Unplug fuel pump module connector (3) [86]. 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION 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. 10. Cut clamp and remove hose from regulator housing fit- ting.

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HARLEY DAVIDSON LED FUEL GAUGE KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Removing the Analog Fuel Gauge NOTE The fuel gauge wires are routed through a tube in the fuel tank, and are secured by a clip at the bottom of the tank and, on some models, a clamp on the frame. Open the clip and clamp as needed, and be sure there is enough slack in the wires to be able to lift out the gauge. 1. At the bottom left side of the fuel tank, bend back the flexible clip slightly to free the fuel gauge conduit. Open the harness clamp on the frame if necessary to free the conduit. Gently pull on the conduit to draw the Multilock connector [117] out of the tunnel. 2. See Figure 2. Depress the pin on the socket terminal side of the connector, and pull apart the pin and socket halves. 3. See Appendix B in an appropriate Service Manual. Use a pick (Snap-On TT600-3 or equivalent) to remove the terminals or clip off the wires. Remove and discard the fuel gauge. 4. For Carbureted Models: See Figure 2. Remove the fuel gauge by firmly grasping and carefully pulling up (do NOT twist) on the gauge just far enough to free it from the fuel tank. Disconnect the two sending unit connectors. Feed the conduit and two wires up through the tube while removing the gauge. Remove and discard the fuel gauge. For Fuel-Injected Models: See Figure 2. Remove the fuel gauge by firmly grasping and carefully pulling up (do NOT twist) on the gauge to free it from the fuel tank. Feed the conduit and three wires up through the tube while removing the gauge. Remove and discard the fuel gauge. 5. Remove and discard the rubber gasket. INSTALLATION For Kit Numbers 75084-04B or 75237-03B 1. See Figure 2. Assemble the new gasket (3) to the LED fuel gauge (1) from the kit. Install the gasket so the flat side contacts the edge of the gauge. 2. See Figure 1. Use three of the Phillips-head screws and washers from the kit to connect the wires as follows: Fasten the Orange wire (1) ring terminal to the gauge connection marked “12V and “O” with a screw and washer. Fasten the Black wire (2) ring terminal to the connection marked “GND” and “BK” with a screw and washer. Fasten the Yellow/White wire (3) ring terminal to the connection marked “Y/W” with a screw and washer. 3. See Figure 2. While carefully lowering the fuel gauge, feed the wire harness (2) down into the drain tube until the three short (Orange, Black, Yellow/White) wires exit the hole at the bottom of the fuel tank. Gently pull the wires to remove slack while installing the gauge to the fuel tank. Do not twist the gauge during installation. Hold the gauge firmly and press down until it snaps into place

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

HARLEY DAVIDSON FUEL LEVEL SENDER ADAPTER BRACKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Remove the currently installed fuel tank from the vehicle. Follow the instructions for the correct model vehicle under FUEL TANK: EFI, REMOVAL in the Service Manual. 3. See FUEL PUMP/FUEL GAUGE SENDING UNIT, REMOVAL in the Service Manual for instructions to: a. Unplug the fuel pump module connector. b. Remove and discard the top plate screws. c. Remove the top plate, fuel pump and fuel level sender (fuel gauge sending unit) from the tank. NOTE Take care to avoid bending the fuel level sender float rod. A bent float rod will lead to erroneous gauge readings. 2 6 1 3 4 7 9 8 5 is05284 1. Fuel level sender 2. Electrical grounding tab 3. Fuel level sender lock tab 4. Adapter bracket 5. Slot (2) 6. Terminal strip insert 7. Sender to adapter lock tab 8. Slider 9. Adapter to tank lock tab Figure 1. Fuel Level Sender Assembly to Adapter – 4. See Figure 1. Clean the electrical grounding tab (2) on the back of the fuel level sender if necessary. The tab must make firm contact with the terminal strip insert (6) in the adapter bracket. Slide the original equipment (O.E.) fuel level sender (1) into the slots (5) in the new adapter bracket (4) as shown until the lock tabs (3 and 7) snap into place. Make sure the wire is not pinched between the adapter and sender. 5. See FUEL SUPPLY CHECK VALVE/TUBE in the Service Manual. Remove the check valve/quick-connect fitting assembly from the old fuel tank, and assemble to the new tank, using a new O-ring (purchased separately). 6. Fit the slider (8) on the adapter bracket into the fuel level sender mounting channel inside the tank, and push down until the lock tab (9) snaps into place. Make sure the sender and adapter wires are not pinched between the adapter and the fuel tank tunnel, and remain accessible through the fuel tank top opening. 7. See Figure 2. Obtain the assembly of the top plate (1), regulator (2) and fuel filter (3) removed from the old fuel tank, and the stainless steel screw (8) and nut (9) provided in this kit.

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HARLEY DAVIDSON LOCKING FUEL FILLER CAP KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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INSTALLATION 1. Prior to installing the gas cap on the vehicle, insert the key into the lock. Firmly grasp the chrome top of the fuel cap and turn the key until it stops. On right hand threaded fuel caps, turn the key counter-clockwise until it stops. On left hand threaded fuel caps, turn the key clockwise until it stops. This assures an unlocked position for the gas cap. Allow the key to return to the neutral position. 2. Remove the key and install the fuel cap on the vehicle. is00770 Figure 1. Right Hand Threaded Fuel Cap Installation NOTE When installing the fuel cap, rotate the cap one full turn past the audible click. This automatically positions gas cap to lock position. A properly locked/installed gas cap will rotate freely in both directions. Failure to do so will give an incorrect assumption that the fuel cap does not work properly. REMOVAL On right hand threaded fuel caps, insert key, and while holding the gas cap in place with hand, turn key counterclockwise until it stops, return key to original position. Gas cap must rotate 270 degrees counter-clockwise before mechanism engages to allow gas cap removal. Continue to rotate counterclockwise to fully remove gas cap. On left hand threaded fuel caps, insert key and while holding the gas cap in place with hand, turn key clockwise until it stops, return key to original position. Gas cap must rotate 270 degrees clockwise before mechanism engages to allow gas cap removal. Continue to rotate clockwise to fully remove gas cap. REPLACEMENT KEYS Record the 4 digit key number stamped on the back of the key opposite the Harley-Davidson logo, in the area provided below. If a replacement key is needed, see your Harley-Davidson Dealer with the 4 digit number to order a replacement

SUZUKI VZR1800K6 And VZR1800/ ZK7 FUEL DELIVERY PIPE REPLACEMENT

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Filed Under (Suzuki) by admin on 26-11-2010

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NOTE: The fuel delivery pipe assembly can be removed from the throttle body without removing the throttle body assembly from the motorcycle. 1) Refer to section 6 of the service manual to remove the fuel tank and the air cleaner box. Place shop rags over the bore of each throttle body to prevent anything from falling into the engine through the throttle bodies. 2) Remove the wire harness clamp, disconnect the fuel injector couplers A and move the harness aside. 3) Remove the four fuel delivery pipe assembly mounting screws and remove the fuel delivery pipe assembly. 4) Replace the o-rings and seals with the new parts supplied in the kit (apply a small amount of engine oil to the o-rings and seals to ease the installation of the injector). To prevent damage to the o-rings or seals, don’t turn the injector when pushing it into the fuel delivery pipe and throttle body respectively. Install the new fuel delivery pipe assembly in the reverse order of removal. 5) Connect the fuel injector couplers A and clamp the injector harness to the fuel delivery pipe. DO NOT overtighten the harness clamp. 6) Connect the fuel tank, remove the shop rags from over the bore of each throttle body, and run the engine, checking for fuel leaks. DO NOT reuse the original fuel hose connector retainer. Confirm that the fuel hose connector has completely seated and locked (clicked) into position before turning on the ignition switch. 7) Refer to section 6 of the service manual to install the air cleaner box and the fuel tank. 8) Test ride the motorcycle to confirm proper operation. FUEL DELIVERY PIPE ASSEMBLY REPLACEMENT PROCEDURE

2001 – '2005 Highlander (V6) FUEL INJECTOR TICKING NOISE

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Filed Under (Toyota Manuals) by admin on 08-10-2011

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Do NOT smoke or work near an open flame when working on the fuel system. Keep gasoline away from rubber or leather parts. Wear safety goggles while working with the fuel system under pressure. Do NOT disconnect any part of the fuel system until you have discharged the fuel system pressure. Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment. 1. Discharge fuel system pressure. A. Remove Circuit Opening Relay from Relay Block No. 1 located to the left of the Instrument Panel Junction Block behind the left lower finish panel If the connector and pipe are stuck, pinch the fuel pipe, push and pull the connector by hand to disconnect them. Do not use any tools. E. Drain the fuel that remains inside Fuel Pipe Sub-assembly No. 1. F. Place a tray under the vehicle or point of disconnection, if needed, to catch any fuel that may spill. G. Protect the disconnected fuel lines from debris by covering with a vinyl or plastic bag. H. Remove the original pulsation damper from the rear fuel rail. I. Remove and discard the remaining bolt holding Fuel Pipe Sub-assembly No. 1 to the front fuel rail

BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

TERMS AND DEFINITIONS OF FUEL INJECTION MANAGEMENT SYSTEMS

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Filed Under (Tips and Review) by admin on 19-11-2010

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Throttle Body Assembly (TBA) — The throttle body assembly (also called air valve), controls the airflow to the engine through one, two or four butterfly valves and provides valve position feedback via the throttle position sensor. Rotating the throttle lever to open or close the passage into the intake manifold controls the airflow to the engine. The accelerator pedal controls the throttle lever position. Other functions of the throttle body are idle bypass air control via the idle air control valve, coolant heat for avoiding icing conditions, vacuum signals for the ancillaries and the sensors. FUEL INJECTOR — There are basically three approaches in delivering the fuel to the engine: • Above the throttle plate as in throttle body injection • In the intake port toward the intake valves as in multi-port injection or central multi-port injection. • Directly into the combustion chamber as in gasoline direct injection systems (GDI). The fuel injector is continuously supplied with pressurized fuel from the electric fuel pump. The pressure across the metering orifice of the injector is maintained constant by the fuel pressure regulator. The fuel injector is an electromagnetic valve that when driven by the ECU delivers a metered quantity of fuel into the intake manifold (or combustion chamber in the GDI system). The ECU controls the fuel flow by pulse width modulation. The time the injector is driven into an open condition is determined by the following sensor inputs: • Engine RPM • Throttle position (TPS) • Manifold absolute pressure or mass air flow • Engine coolant temperature • Oxygen sensor feedback voltage • Intake air charge temperature • Battery voltage CENTRAL POINT INJECTION SYSTEM (CPI) — Electronic fuel Injection system consisting on a single fuel injector mounted in the throttle body. DIGITAL FUEL INJECTION (DEFI OR DFI) — Electronic fuel injection system controlled by digital microprocessors as opposed to earlier systems that were of analog design. The analog input signals to the microprocessor are converted from analog to digital before being processed.

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