INTAKE AIR TEMPERATURE SENSOR (IAT)

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INTAKE AIR TEMPERATURE SENSOR (IAT) 4.8 Refer to the ELECTRICAL DIAGNOSTIC MANUAL for information on the function and testing of the intake air temperature sensor (IAT sensor).

1 INTAKE AIR TEMPERATURE SENSOR (IAT) 4.8 Refer to the ELECTRICAL DIAGNOSTIC MANUAL for information on the function and testing of the intake air temperature sensor (IAT sensor). sm054 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a). Disconnect negative battery cable.. Remove air cleaner backplate. See 4.5 AIR CLEANER. See Figure 4-. Unplug IAT sensor connector [89]. 4. Remove fastener to detach IAT sensor. Discard fastener.. See Figure 4-. Inspect O-ring () in groove of intake air temperature sensor for cuts, tears or signs of deterioration. Install new O-ring if necessary.. See Figure 4-. Insert sensor into induction module with electrical connector facing toward the left side of the motorcycle.. See Figure 4-. Install fastener () and tighten to 5-0 in-lbs (.7-. Nm). 4. Connect IAT sensor connector [89]. 5. Install air cleaner assembly. See 4.5 AIR CLEANER 6. Connect negative battery cable. Figure 4-. Intake Air Temperature Sensor Location sm055. O-ring. Fastener Figure 4-. Intake Air Temperature Sensor 009 Dyna Service: Fuel System 4-

ENGINE TEMPERATURE SENSOR (ET) 4.9 sm088 Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline.

(0000a) Refer to the ELECTRICAL DIAGNOSTIC MANUAL for information on the function and testing of the engine temperature sensor (ET sensor). Figure 4-.

Remove the fuel pump fuse from the fuse block. b. Start the engine and allow the vehicle to run. c.

2 ENGINE TEMPERATURE SENSOR (ET) 4.9 sm088 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 ELECTRICAL DIAGNOSTIC MANUAL for information on the function and testing of the engine temperature sensor (ET sensor). Figure 4-. Fuel Pump Fuse 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-. Remove the fuel pump fuse from the fuse block. 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. sm0 Gasoline can drain from quick-connect fitting when removing fuel line. 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. (0067a). See Figure 4-4. Pull up on chrome sleeve of quick-connect fitting () and pull down on fuel supply line () to disconnect.. Quick connect fitting. Fuel supply line sm0604 Figure 4-4. Fuel Supply Line Fitting 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. See Figure 4-5. Pull back boot to reveal ET sensor at back of front cylinder. 5. Unplug ET sensor connector [90] by pulling external latch outward and using rocking motion to remove. 6. See Figure 4-6. Loosen ET sensor using socket. When sensor starts to turn easily, finish removing by hand. Figure 4-5. Engine Temperature Sensor Dyna Service: Fuel System

sm0605. Hand start new ET sensor into cylinder head bore - turns.. Tighten sensor to 0-5 ft-lbs (.6-0. Nm).. Connect ET sensor connector [90]. 4. Pull boot over connector. 5.

3 sm0605. Hand start new ET sensor into cylinder head bore - turns.. Tighten sensor to 0-5 ft-lbs (.6-0. Nm).. Connect ET sensor connector [90]. 4. Pull boot over connector. 5. See Figure 4-4. Install fuel line fitting. 6. See Figure 4-. Install fuel pump fuse. 7. Connect negative battery cable. Figure 4-6. Engine Temperature Sensor Removal 009 Dyna Service: Fuel System 4-5

4 INDUCTION MODULE 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). Gain access to the induction module by removing fuel tank hardware and fuel line. Carefully pivot tank upward and prop in position. See 4.6 FUEL TANK.. Remove air cleaner backplate. See 4.5 AIR CLEANER 4.0. See Figure 4-7. Pull purge hose from fitting (5) at top of induction module (California models only). 4. See Figure 4-8. Pull idle cable barrel () from upper hole in throttle wheel. Pull throttle cable barrel () from lower hole. Using slots, release idle and throttle cables from guides in throttle cable bracket. 5. See Figure 4-7. Remove idle air control connector () [87] and manifold absolute pressure sensor connector (7) [80]. 6. Remove front fuel injector connector () [84] and rear fuel injector connector (8) [85]. 7. Remove throttle position sensor connector (4) [88] and intake air temperature sensor connector (6) [89]. sm Front fuel injector [84] 7. MAP sensor [80]. Throttle cable bracket 8. Rear fuel injector [85]. IAC connector [87] 9. Rear mounting flange 4. TP sensor [88] 0. Fuel supply tube 5. Purge hose fitting (used on California models only). Front mounting flange 6. IAT sensor [89] Figure 4-7. Induction Module 8. On left side of vehicle, loosen two hex screws holding front and rear mounting flanges (9, ) to cylinder head. 9. On right side of vehicle, remove two Allen screws holding front and rear mounting flanges to cylinder head. Remove induction module from vehicle. Gasoline can drain from the fuel line when disconnected from induction module. 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. (0069a) Dyna Service: Fuel System

0. See Figure 4-0. If fuel supply line () is being replaced, squeeze ends of tab () and pull tab away from fuel supply line to release from fuel supply tube ().. Remove seals from flange adapters.

5 0. See Figure 4-0. If fuel supply line () is being replaced, squeeze ends of tab () and pull tab away from fuel supply line to release from fuel supply tube ().. Remove seals from flange adapters. Discard seals. Remove flange adapters from outlet ports of induction module. sm057 4 housing into cable guide at bottom of throttle cable bracket inserting barrel end () into upper hole in throttle wheel. 5. See Figure 4-7. On California models, attach purge hose to fitting (5) on throttle body. 6. Connect front () and rear (8) fuel injector connectors, IAC () connector, MAP sensor (7) connector, TP sensor (4) connector and IAT (6) sensor connector. 7. Install air cleaner back plate. See 4.5 AIR CLEANER 8. Tighten manifold mounting screws to in-lbs ( Nm). 9. Turn the Ignition/Light Key Switch to ON and then back to OFF to reset idle air control to park position. 0. Install air cleaner filter and cover.. Secure fuel tank. See 4.6 FUEL TANK. sm058. Idle cable barrel. Throttle cable barrel. Throttle wheel 4. Throttle cable bracket Figure 4-8. Throttle/Idle Cables. See Figure 4-7. Place a new seal in each mounting flange (9, ) with the beveled side in against the counterbore. NOTE When induction module is positioned on manifold mounting screws, be sure the flanges are installed correctly on the manifold. Be sure the rubber seals are in place.. Place intake manifold seal, flanges, and induction module in position. Install the manifold mounting screws finger tight.. See Figure 4-0. Slide fuel supply line () onto fuel supply tube (). Push in on tab until it locks the fuel supply line () on fuel supply tube (). Tug on fuel supply line () to verify it is locked into place. 4. See Figure 4-8. Install sleeve on throttle cable housing into cable guide at top of throttle cable bracket (4). Drawing throttle cable downward, fit barrel end () into lower hole in throttle wheel (). Install sleeve and spring on idle cable sm0756 Figure 4-9. EVAP Hose Connection. Tab. Fuel supply line. Fuel supply tube Figure 4-0. Fuel Supply Line 009 Dyna Service: Fuel System 4-7

6 IDLE AIR CONTROL (IAC) 4. sm059 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 ELECTRICAL DIAGNOSTIC MANUAL for information on the function and testing of the idle air control (IAC).. Remove induction module. See 4.0 INDUCTION MODULE.. See Figure 4-. Remove two fasteners () to release throttle cable bracket () from induction module. Discard fasteners.. See Figure 4-. Pull IAC () and O-ring () from throttle body. sm0607. Idle air control (IAC). O-ring Figure 4-. Idle Air Control. See Figure 4-. Apply clean engine oil to IAC O-ring (). Install O-ring in counterbore of induction module.. With the electrical connector facing the rear left side of the induction module, install idle air control into bore.. Place idle air control and o-ring into throttle body. Be sure o-ring is properly seated in throttle body groove. 4. See Figure 4-. Insert index pin () at bottom of throttle cable bracket () into hole in boss at top of induction module. 5. See Figure 4-. Install new throttle cable bracket fasteners (). Tighten to 0-5 in-lbs (.-4.0 Nm). 6. Install induction module. See 4.0 INDUCTION MODULE.. Throttle cable bracket. Fasteners. Idle air control (IAC) Figure 4-. Idle Air Control Location sm090. Throttle cable bracket. Index pin Figure 4-. Throttle Cable Bracket Dyna Service: Fuel System

MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 4. Refer to the electrical diagnostic manual for information on the function and testing of the temperature/manifold absolute pressure (TMAP) sensor.

7 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 4. Refer to the electrical diagnostic manual for information on the function and testing of the temperature/manifold absolute pressure (TMAP) sensor.. Remove induction module. See 4.0 INDUCTION MODULE.. See Figure 4-4. Remove two fasteners () to release throttle cable bracket () from induction module. Discard fasteners.. Using appropriate tool, gently push up on MAP sensor and attached seal to remove from intake manifold.. With the electrical connector facing toward the rear of the induction module (side opposite throttle wheel), insert MAP sensor into hole in induction module.. See Figure 4-6. Insert index pin () at bottom of throttle cable bracket into hole in boss at top of induction module. 4. See Figure 4-4. Install new throttle cable bracket fasteners (). Tighten to 0-5 in-lbs (.-4.0 Nm). 5. Install induction module. See 4.0 INDUCTION MODULE. sm060 sm0608. Seal. MAP sensor Figure 4-5. MAP Sensor. Throttle cable bracket. Fasteners. Manifold Absolute Pressure Sensor (MAP) Figure 4-4. Throttle Cable Bracket Location NOTE See Figure 4-5. If the original sensor is re-installed, the seal () must be inspected. Seals not in good condition could cause vacuum leaks. Install new seal if necessary.. Push MAP sensor and seal into intake manifold. sm090. Throttle cable bracket. Index pin Figure 4-6. Throttle Cable Bracket 009 Dyna Service: Fuel System 4-9

AIR CLEANER GENERAL REMOVAL. 1CAUTION Do not run engine without filter element in place. Debris could be drawn into the engine causing damage.

AIR CLEANER GENERAL REMOVAL. 1CAUTION Do not run engine without filter element in place. Debris could be drawn into the engine causing damage. AIR CLEANER GENERAL The air cleaner prevents foreign material from entering the carburetor and engine by trapping airborne dust and dirt in the filter element. Service air cleaner filter element every