INDUCTION MODULE HARDWARE KIT
J027082012-03-13
GENERAL
Kit Number
27635-01B
Models
This kit fits:
- all 2002 and later Fuel Injected FL Touring models.
- all 2001 and later Fuel Injected Softail models.
Installation Requirements
Loctite® 290 Threadlocker and Sealant - Green (Part No. 99809-97) is required for proper installation of this kit.
Electrical Contact Lube (H-D Part No. 99861-02) or equivalent is required after battery cable disconnection. These items are available from a Harley-Davidson dealer.
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
PREPARATION
NOTE
For vehicles equipped with security siren:
- 2007 and later: Verify that the Hands-Free Fob is present. Turn the ignition key switch to IGNITION.
- 2006 and earlier: Disarm the siren with the key fob.
WARNINGTo 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)
See the service manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line.
For Vehicles With Main Fuse:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- See the service manual and remove the main fuse. Remove the seat. Retain the seat and all mounting hardware.
For Vehicles With Main Circuit Breaker:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
- See the service manual to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware.
For ALL models:
WARNINGWhen 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)
INSTALLATION
| 1. | Remove the induction module, and separate the throttle body from the intake manifold per the service manual. | |||||
| 2. | FL Touring models: See the service manual to remove the fuel rail and fuel supply tube. Retain the fuel tube clip for later installation. The washer and O-ring beneath the clip can be discarded. | |||||
| 3. | ALL models: Remove the fuel injectors per the service manual. | |||||
| 4. | See Figure 1. Remove and discard the two O-rings (1) from each of the fuel injectors. | 
Figure 1. Fuel Injector | ||||
| 5. | See Figure 2. Apply a thin coat of clean engine oil to the new fuel injector O-rings (1) from the kit. Install the O-rings onto the fuel injectors. | |||||
| 6. | With the electrical connectors facing upward, push the fuel injectors into the induction module bores. Rotate the fuel injectors so that the electrical connectors are on the outboard side. | |||||
| 7. | Push the fuel rail (B) over the fuel injectors until the fuel rail flange contacts the boss on the induction module. NOTE Measure the fuel rail mounting flange thickness (C) before selecting the mounting screws from the kit. If the flange thickness is 6 mm (¼ in), use the 14 mm (9/16 in) long screws (3). If the flange thickness is 9 mm (⅜ in), use the 17 mm (11/16 in) long screws (4). | |||||
| 8. | Use two screws (item 3 or 4, see note above) from the kit to fasten the fuel rail to the induction module. Alternately tighten the screws to 3–3.7 N·m (27–33 in-lbs). NOTE Select the fuel tube mounting screw from the kit. If the threaded hole is drilled through the top, as shown in the illustration, use a 17 mm (11/16 in) long screw (4). If the threaded hole is a blind hole, use a 14 mm (9/16 in) long screw (3). | |||||
| 9. | Get the fuel tube clip (F) removed earlier. Select the sealing washer (5), O-ring (6), and the correct screw from the kit. Align the hole in the fuel supply tube clip with the hole in the fuel rail. Install the screw and tighten to 3–3.7 N·m (27–33 in-lbs). Rotate the fuel supply tube (E) so that it angles downward. | |||||
| WARNING Gasoline will leak if fuel line is loose. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00367a) | ||||||
| 10. | Verify that the clip is holding the fuel tube tight. If it is not, remove the items just assembled and clean the threads as necessary to make sure the fuel tube is tightly secured. | |||||
| 11. | See the service manual to assemble the throttle body and intake manifold using the large O-ring (2) and two screws (4) from the kit. Apply 1-2 drops of Loctite 290 (Green) to the end of each screw. Tighten the screws to 3–3.7 N·m (27–33 in-lbs). | |||||
| 12. | Install the induction module to the cylinder heads. |
RETURN TO SERVICE
NOTE
To prevent possible damage to the sound system (if equipped), verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the battery cables.
- Models with main fuse: See the service manual and install the main fuse.
WARNINGConnect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
| 1. | Models with main circuit breaker:See the service manual and attach the battery cables (red positive cable first). Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. | |
| WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||
| 2. | For ALL models: See the service manual and install the seat. | |
| 3. | Start the motorcycle and check for proper engine operation and fuel leaks. |
SERVICE PARTS
Figure 2. Service Parts, Induction Module Hardware Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | O-ring, metric injector (4) | Not sold separately |
2 | O-ring, throttle body to intake manifold | Not sold separately |
3 | Screw, TORX® head, M4-0.7 x 14 mm (0.55 in) (3) | Not sold separately |
4 | Screw, TORX® head, M4-0.7 x 17 mm (0.67 in) (5) | Not sold separately |
5 | Washer, fuel tube sealing | Not sold separately |
6 | O-ring, fuel tube | Not sold separately |
Items mentioned in text. | ||
A | Intake manifold | |
B | Fuel rail | |
C | Measure flange thickness to select screw (3) or (4) | |
D | Threaded blind or through hole to select screw (3) or (4) for clip (5) | |
E | Fuel tube | |
F | Fuel tube clip (Part No. 27627-01) | |