INSTRUCTION FOR EFI FUEL PRESSURE GAUGE TOOL

Transcription

1 INSTRUCTION FOR EFI FUEL PRESSURE GAUGE TOOL This gauge is now a must have new tool, as 90% of all Big Twins motorcycles have Electronic Fuel injection. (EFI). If you have a customer that is experiencing any of the following conditions: Hesitation under acceleration Loss of power Back firing through the intake Poor fuel economy Stalling out Engine turns over but will not start. Just to name a few symptoms that an improper fuel system pressure may contribute too. This Fuel pressure gauge is easily installed in-line with the motorcycles fuel supply system. All fuel testing needs to be performed with the engine running. With this tool we supply you with all the necessary hose connections to make this test in about the same amount of time it takes to change a set of spark plugs. INSTRUCTIONS FOR FUEL PRESSURE GAUGE Read complete instructions throughly before assembling or using this tool. Tools needed 1/4 drive deep 11/32 socket T-25 Torx bit Jim s set No.1773, for 2008 FL models 1/4 torque wrench (in-lbs) 1/2 crows foot Fire extinguisher capable of putting out a gas fire. H/D services manual or equivalent for the motorcycle you will be testing. If the fuel pressure is not within specifications then the manual will help guide you to other diagnosis. IF YOU DO NOT KNOW WHAT YOU ARE DOING, DO NOT DO IT! WORKING WITH GASOLINE IS VERY DANGEROUS AND HIGHLY EXPLOSIVE. WHEN YOUR WORKING ON THE FUEL SYSTEM DON T SMOKE OR HAVE ANY SPARKS OR OPEN FLAMES ANYWHERE NEAR YOUR SERVICE AREA. YOUR LIFE DEPENDS ON THE SAFETY PRECAUTIONS YOU TAKE. NON-SUFFICIENT SAFETY PRECAUTIONS COULD RESULT IN DEATH OR SERIOUS INJURY. No information in this instruction sheet pertaining to motorcycle repair is represented as fool proof or even all together safe. Even something safe, done incorrectly or in completely can and will backfire in this case explode and cause serious injury. You and only you are responsible for the safety of your repair work and for your understanding the application and use of repair equipment, components, methods and concepts. Each and every step that this tool is designed to do must be carefully and systematically performed safely by you. All information listed in this instruction sheet has been tested, re-tested and used daily in JIMS Research and Development Department. 1

2 ALWAYS WEAR SAFETY GLASSES OR OTHER FACE AND EYE PROTECTION SUCH AS FULL FACE SHIELD, OVER YOUR EYES AND FACE. JIMS is not responsible for damage, injury, or your work! JIMS IS NOT RESPONSIBLE FOR THE QUALITY AND SAFETY OF YOUR WORK WARNING: Gasoline is extremely explosive and highly flammable, both could result in death or serious injury. Do not smoke or have any flames anywhere around the use of this tool including gas fired water heaters. All spilled fuel needs to be remove immediately and delt with in a suitable manner. Wear safety glass over your eyes. If any fuel gets on any part of your body wash it off. To avoid any fuel that may be under pressure when removing fuel lines you must first purge (relieve fuel pressure). Locate and remove the 15-amp fuel pump fuse. Start the engine letting it idle until engine stalls, try to restart the engine for 3 to 4 more seconds. This will help remove fuel from the fuel lines. Caution: After each use of this tool, you must drain all the tool test lines of all fuel! SEE PURGING LINES paragraph on page 4. This will be explained later on in this instruction sheet. Note: Do not apply any Loctite to the threads of one way fuel valve assembly No when assembling fuel lines. This is the fitting with black plastic cap. See Fig FIG PARTS AVAILABLE SEPARATELY No. Qty. Description Part No. 1 1 GAUGE ASSEMBLY HOSE, 8 INCH LONG HOSE, 2 FOOT LONG HOSE, FUEL TANK CONNECTION HOSE, THROTTLE BODY CONNECTION 6 1 HOSE,CLEAR, W/NUT, OVERFLOW TEE-FITTING VALVE ASSEMBLY / ONE WAY BALL VALVE / IN LINE NEEDLE VALVE / BLEEDER ADAPTER, 08 TO PRESENT TUBE SLEEVE, 1/ LOCTITE # TOOL CASE INSTRUCTION SHEET 955-IS BLACK RELEASE CLIP SHOWN IN OFF POSITION 2 8 FIG

3 ASSEMBLING TOOL Start by removing all parts of tool from its storage box. The pressure gauge head has been assembled with one of the supplied tee fittings. Do not remove this brass tee fitting. In the following text you will be instructed to apply Loctite. When doing this apply two small drops of supplied Loctite to both the I.D. and O.D. of all brass threads. Note: Do not apply any Loctite to the threads of fuel valve assembly No on the fuel line. This is the fitting with black plastic cap. See Fig. 7. A. Hand thread the brass T-handled bleeder valve, No (using the tapered pipe threads on valve) into the side hole of the tee fitting that is already installed on the end of gauge. Mount your 1/2 crows foot, on the square surface of the bleeder valve body and torque the to 45 in-lbs. Stop when the compression threads are pointing away from gauge. See Fig.2. Use supplied Loctite on all threads. B. Thread rubber hose No that is 2 ft. long, to the bottom of tee fitting that now has the tee-valve and gauge connected to it. Use supplied Loctite on all threads. Torque to 45 in-lbs. See Fig. 3. C. Next install black handle ball valve No with to other end of hose that you just installed to tee fitting and valve. Use supplied Loctite on all threads, torque to 45 in lbs. See Fig. 4. D. Install the hex male pipe threaded end of 8 short hose No onto the other end of ball valve No Use supplied Loctite on all threads, and torque to 45 in-lbs. See Fig. 5. E. Holding the other tee fitting No.955-4, install hose No and to tee fitting No as shown in Fig. 6. Use supplied Loctite on all threads and torque to 45 in-lbs. F. Next install the valve assembly with black cap No into the middle threaded hole of tee fitting and use supplied Loctite only threads as shown and torque to 45 in-lbs. See Fig.7. Note: Do not apply Loctite to the threads under black cap. G. Locate clear overflow hose No in bag with a brass nut and black sleeve. Note that the taper on sleeve faces toward taper inside the brass nut. Lube O.D. of hose and sleeve and then insert end of hose into needle valve No Slide nut over sleeve and thread onto valve as shown. See Fig.8. Gauge FIG.2 FIG.3 No FIG.4 No FIG FIG.7 No Shown in off position LOCTITE THIS THREAD SURFACE ONLY No No No SCREW DOWN TO CLOSE VALVE Taper side FIG.6 FIG.8 LUBE

4 WARNING: Testing for fuel leaks: The first time you connect this tester up to fuel pressure make sure to check for any fuel leaks from any of the fittings before starting the engine. Testing for fuel leaks: After installing the pressure gauge to engine you must check your assembly work. Follow the instruction listed below (for installing pressure gauge) Do not smoke or have any open flames. Work area should be well ventilated. Turn the ignition switch on and off a few times. Note: Do not allow the switch to be on for more then 2 seconds. Look over all fittings for any signs of wet fuel. If leaks are found repair that fitting and retest until there is NO FUEL LEAKS at any of the installed fittings or any fuel line connections. Gasoline is extremely explosive and highly flammable. Both could result in death or serious injury. Do not smoke or have any open flames anywhere around the use of this tool, including gas fired water heaters. All spilled fuel needs to be remove immediately and contained in a suitable manner. Wear safety glasses over your eyes, if any fuel gets on any part of your body wash it off. PURGING FUEL LINES To avoid any fuel that may be under pressure when removing fuel lines you must first purge (relieve fuel pressure). Locate and remove the 15-amp fuel pump fuse, See Fig 9. Start the engine and let it idle until engine stalls. Try to restart the engine 3 to 4 times. This will help remove most all fuel from the fuel lines. FIG.9 INSTALLING THE PRESSURE GAUGE ON 2002 TO 2008 DYNA S, SOFTAIL S, AND 2002 TO 2007 FL MODELS. 1. You may need to remove the top motor mount depending on your ability and tools to gain access to the fuel rail mount. From the left side of tank you will be removing the fuel supply line from the tank. Do this by pushing up (sliding) on the chrome outer sliding sleeve of the quick-connect fitting and at the same time gently pulling down on fuel line. See Fig 10. Next reach up under tank at the other end of fuel line and with your finger or a blunt screw driver press in on the blue release slid located on the connector. Gently pull off hose from fuel rail supply tube. Outer sleeve FIG.10 Black Release Button Caution: A small amount of fuel may drip from either end of fuel line. 4

5 Note: Use a clean rag over both ends of the line being removed, as some small amount of fuel may still be inside the line. 2. With both ends of stock fuel line removed, apply a small amount of lube to I.D. of connectors of tool hose test lines No and No.. 3. Install the connector end with the black button on test line No. over fuel rail supply tube. This is the same location you just removed the stock fuel line from. It will click in place. Gently pull on line making sure it is locked in place. Fuel Rail 4. Next install the other end of tool test hose No into the fuel sup ply fitting on the left side of tank. See Fig 11. This is the same way you removed the stock fuel line. It will click in place. Gently pull down on test LUBE line making sure it is locked in place Caution: Make sure both ends of test line cannot and will not come lose. FIG Remove black plastic cap and apply a small amount of lube to the male threads of No valve assembly connected to the tee fitting of the test hose you just installed to the fuel tank. See Fig.11 Shown in off position No Hose Note: Turn T-handle clockwise on bleeder valve to close and No Close Ball valve No to the off position. See Fig. 19 on page 7. FIG Note: Close the No bleeder valve by screwing clockwise on the Tee-handle. See Fig.8. Also on the in-line fuel valve, No.955-8, put the blue lever in the off position. See on/off markings on blue lever. See Fig Thread on tool test hose No onto the lubed No valve assembly, a snug finger tight only. See Fig Reinstall the 15-Amp fuel pump fuse. Turn ignition switch on and off, leaving it in the on position for only 2 seconds.see Fig.9 9. Inspect all fittings for being fuel leak free. 10. Place the open end of clear overflow hose No into a gas can. See Fig 13. Note: Do not allow hose to come out of gas can, as the system is being bled of all air and fuel If no fuel leaks have been detected, start engine letting idle; then slowly open the fuel in line test valve No FIG.13 5

6 12. Slowly turn Tee-handle counter clockwise to open the bleeder/ overflow test valve No until all air has been purged from the test hoses. Note: Do not open the bleeder test valve any further to show 20 P.S.I. on gauge. Any lower may stall the engine. 13. Idle, then open throttle to 2500-RPM if fuel P.S.I. is less, see H-D service manual for repair fuel P.S.I.. Needs to be holding between P.S.I. 14. Turn off engine after test is completed with fuel gauge, open air bleeder valve No until all fuel his drained from the system. Caution: Let engine cool before removing and test hoses and before reinstalling the stock fuel lines. 15. After installing any fuel line or lines, be sure to check for any fuel leaks. 16. After draining all fuel from fuel P.S.I. gauge, place it back in it s case for safe keeping. INSTALLING PRESSURE GAUGE ON 2008 FL MODELS Stock Fuel Line 1. If installing on a 2008 FL models, you may need to remove top motor mount depending on your ability and tools to gain access to the fuel rail mount. 2. Remove retaining 5 Torx screw holding the lock bar. Note how it is installed for reinstalling with your #25 Torx bit. See Fig 14. Note: The location of o-rings and washers from fuel line end. 3. Follow your 2008 FLH service manual for the removal of fuel line. Also from the left side of tank you will be removing the fuel supply line from the tank. By pushing up (sliding) on the chrome outer sliding sleeve of the quick-connect fitting and at the same time gently pulling down on fuel line. See Fig 10. FIG.14 OUTER SLEEVE #25 Torx socket 4. Gently push either end of fuel adapter No into test line No. until it clicks in directional as shown in Fig 16. Pull on the other end to make sure it is locked in. Install the o-rings and washers in the same order as they were removed from the stock line onto the end of the adapter. See Fig 16. FIG Gently install the hose No. with fuel adapter No , into fuel rail FIG with locking bar and tighten retaining Torx screw. See service manual for the amount of torque applied to screw. See Fig 14. 6

7 Install the other end of line No into the fuel supply fitting on left tank, the same way you removed the stock fuel line. It will click in place. Gently pull down chrome lock sleeve also pull down on test line making sure it is locked in place, Fuel Rail Caution: Make sure both ends of test line cannot and will not come lose. See Fig Remove black plastic cap and apply a small amount of lube to the male threads of No valve assembly connected to the tee fitting of the test hose you just installed to the fuel tank. See Fig 17. Note: Turn T-handle clockwise on bleeder valve to close and No Close Ball valve No to the off position. See Fig Reinstall the 15-amp fuel pump fuse, turn ignition switch on and off (leaving it in the on position for 2 seconds only.) See Fig Check all fittings for being fuel leak free. 9. Place the open end of clear fuel bleed hose No in a gas can. See Fig 18. Note: Do not allow hose to come out of gas can, as the system is being bled of all air. See Fig If no fuel leaks have been detected, start engine letting it idle; slowly open the fuel in line ball valve No , See Fig 19. Note: Do not open the bleeder test valve any further to show 20 P.S.I. on gauge. Any lower of a setting and the engine may stall. 11. Slowly open the (needle valve) bleeder test valve No until all air has been purged from the test hoses. See Fig 20. FIG.18 Shown in off position FIG FIG LUBE No Hose Turn counter clockwise to open 12. Open throttle to 2500-RPM,if fuel P.S.I. is less, see H-D service manual for repair fuel P.S.I. guage. Needs to be holding between P.S.I. FIG Turn off engine after the test is completed with fuel test gauge, open air bleeder valve No until all fuel his drained from the system. See Fig 20. Caution: Let engine cool before removing any test hoses and before reinstalling the stock fuel lines. 14. After installing any fuel line or lines be sure to check for any fuel leaks. After draining all fuel from fuel P.S.I. gauge, place it back in its case for safekeeping. 7