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INDUCTION MODULE HARDWARE KIT
J039492005-11-15
GENERAL
Kit Number
27700-07
Models
This kit fits 2007 and later XL (Sportster®) models.
Additional Parts Required
Loctite® 290 (green) Threadlocker and Sealant (Part Number 99809-97) will be needed for proper installation of this kit.
WARNING
Rider 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 references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Kit Contents
Table 1. Kit Contents
Description (Quantity)
Part Number
"O"-ring, metric injector (4)
Not Sold Separately
"O"-ring, throttle body to
intake manifold
Not Sold Separately
Screw, throttle body to
intake manifold (2)
Not Sold Separately
INSTALLATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
1. Refer to BATTERY DISCONNECTION AND REMOVAL in the Service Manual, and follow the instructions given to disconnect the negative (-) battery cable at the engine crankcase.
WARNING
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. See INDUCTION MODULE ASSEMBLY: REMOVAL in the Service Manual, and follow the instructions to remove the air cleaner and backplate, fuel tank and induction module.
WARNING
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. (00269a)
3. Follow the instructions to disconnect the fuel supply line from the fuel supply tube.
1Flange adapter (2)
2Intake manifold seal (2)
3Throttle body to intake manifold screw (2)
4Throttle body
5Intake manifold
6Throttle body "O"-ring
Figure 1. Sidedraft Induction Module Assembly
4. See Figure 1. Remove the flange adapters (1) from the outlet ports of the induction module. Remove the intake manifold seals (2) from the flange adapters. Note the condition of the seals and replace if necessary.
5. Use a T-20 TORX® drive head to remove the two M4 screws (3) securing the throttle body (4) to the intake manifold (5). Discard the screws. Separate the two halves of the induction module. Remove and discard the "O"-ring (6).
6. See Figure 2. Orient the intake manifold (6) with the fuel rail facing upward. Align the intake manifold and throttle body mounting holes, and re-assemble using the new "O"-ring (1) and two screws (2) from the kit. Alternately tighten the screws to 35 in-lbs (3.9 Nm). Apply 1-2 drops of Loctite® 290 (Threadlocker) to the edge of each screw head to prevent the screws from loosening.
1Throttle body "O"-ring
2Throttle body to intake manifold screw (2)
3Fuel injector "O"-ring (4)
4Fuel rail (not part of kit)
5Fuel injector (2) (not part of kit)
6Intake manifold (not part of kit)
Figure 2. Hardware Kit Components
7. Remove the fuel rail (4) and fuel injectors (5) from the intake manifold as an assembly (see FUEL SUPPLY TUBE/ FUEL RAIL/ FUEL INJECTORS, REMOVAL in the Service Manual). Remove the fuel injectors from the fuel rail.
1"O"-ring (2)
2Electrical connector
Figure 3. Fuel Injector
8. See Figure 3. Remove and discard the two "O"-rings (1) from each of the fuel injectors.
9. See FUEL SUPPLY TUBE/ FUEL RAIL/ FUEL INJECTORS, INSTALLATION in the Service Manual and Figure 2. Apply a thin coat of clean engine oil to the new fuel injector "O"-rings (3) from the kit. Install the "O"-rings onto the fuel injectors.
10. Install the fuel injectors into the intake manifold bores per the Service Manual instructions. Install the fuel rail over the fuel injectors.
11. Refer to INDUCTION MODULE ASSEMBLY: INSTALLATION in the Service Manual, and follow the instructions given to re-install the fuel supply line to the fuel supply tube. Install the induction module.
12. Follow the instructions to install the fuel tank, air cleaner and backplate.
13. Refer to BATTERY INSTALLATION AND CONNECTION in the Service Manual, and follow the instructions to re-connect the negative (-) battery cable at the engine crankcase.
14. Start the motorcycle and check for proper engine operation and fuel leaks.