EFI INTAKE MANIFOLD COVER
J039972006-10-09
GENERAL
Kit Numbers
27483-07A
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of this kit requires Loctite® 243, Harley-Davidson Part Number 99642-97.
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 references Service Manual information. A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer.
INSTALLATION
| 1. | See Figure 1. Remove screw (A) that holds the air cleaner cover (B) and seal (C). | |
| 2. | Remove three T27 TORX® screws (D) to release the cover bracket (E) from the filter element (F). | |
| 3. | Remove the filter element, pulling the two breather tubes (G) from hole on the inboard side of element. | |
| 4. | Remove the two breather tubes (G) from the fittings on the two cylinder head breather bolts (I). | |
| 5. | Remove the two breather bolts (I) and O-ring seals (K) from the air cleaner backplate (J) with a 7/16 inch deepwell socket. | |
| 6. | Remove the backplate and gasket (H) from the injection module. | |
| 7. | Aligning the flat edge of a new cover gasket (2) with the backplate molded tab, install a gasket (2), chrome cover (1) and second gasket, in order, on the air cleaner backplate. | |
| 8. | Install the breather bolts through the air cleaner backplate. Re-install O-ring seals onto each breather bolt. Install a washer (3) from the kit on each breather bolt. Apply Loctite 243 to the breather bolts and align holes in the backplate with the holes in the cylinder heads and install the breather bolts. Use a 7/16 inch deepwell socket and alternately tighten the breather bolts to 13.6–16.3 N·m (120–144 in-lbs). | |
| 9. | Slide gasket over the sleeve on the inboard side of filter element. | |
| 10. | Install breather tubes about 1/4 inch (6.4 mm) into holes on inboard side of filter element. | |
| 11. | Install breather tubes onto fittings of two cylinder head breather bolts. NOTE Air cleaner mounting without installation of the breather tubes allows crankcase vapors to be vented into atmosphere in violation of legal emissions standards. | |
| 12. | Place the filter element onto backplate, with the flat side down, so that the hole on the inboard side of element fits over the molded boss in the backplate. | |
| 13. | Align holes in cover bracket with those in filter element and start three screws. Stamp on cover bracket points downwards. Use a T27 TORX drive head, alternately tighten screws to 2.3–4.5 N·m (20–40 in-lbs). | |
| 14. | Make sure that the rubber seal is proper seated around perimeter of air cleaner cover and place cover on backplate. | |
| 15. | Fit the air cleaner cover onto backplate. Apply Loctite 243 to the threads of air cleaner cover screw. Install screw through cover and tighten to 4.1–6.8 N·m (36–60 in-lbs). |
SERVICE PARTS
Figure 1. Service Parts: Chrome EFI Cover
Table 1. Service Parts: Chrome EFI Cover
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Cover, EFI | Not Sold Separately | E | Bracket, air cleaner cover | ||
2 | Gasket, EFI cover (2) | 27486-07 | F | Element, air cleaner | ||
3 | Washer (2) | 46465-99 | G | Breather tube | ||
Items mentioned in text but not in kit: | H | Air filter gasket | ||||
A | Air cleaner screw | I | Breather bolt | |||
B | Air cleaner cover | J | Air cleaner backplate | |||
C | Air cleaner cover seal | K | O-ring seal | |||
D | Screw | |||||