Dealers carry service manuals with instructions for replacing a fuel injector.
Harley-Davidson’s 2001 Road King and Electra Glide motorcycles feature twin-cylinder 1,449 cc engines with electronic fuel injection. Typically, poor throttle response, along with reduced engine performance, indicates one of the fuel injectors is faulty. Fuel injectors for the front and rear cylinders are located on the fuel induction module between the cylinders. Replacing the front injector is relatively easy. The most time-consuming part of the job is removing certain external components to access the injector. Those with limited knowledge of these motorcycles should enlist the assistance of a qualified Harley-Davidson technician.
1. Remove the chrome air cleaner cover at the right side of the engine. Remove the horn at the left side of the engine and disconnect the wire at the back of the horn.
2. Loosen and remove the mounting bolts at the underside of the rider’s seat. Lift the seat off and set it aside. Save the bolts.
3. Turn off the fuel supply at the underside of the gas tank. Loosen and remove the bolt where the front of the tank mounts at the steering head. Save the bolt.
4. Lift the rear of the tank enough to disconnect the vapor valve line that connects at the right side. Detach the front and rear check-valve body assemblies from the underside of the tank.
5. Lift the gas tank enough to disconnect the gauge wires and ignition wires that run from the instrument console on top of the tank to the plug-in connectors near the steering head. Lift off the gas tank and set it aside.
6. Identify the pair of fuel injectors at the top of the fuel induction module. Detach the sensor wire at the plug-in connector on the front injector. Remove the retainer screw and clip from the face of the front injector. Save the screw and the clip. Pull the injector out of the port on the induction module.
7. Apply lightweight oil into the O-ring recesses on the new injector. Fit the larger O-ring into the recess at the upper end of the injector. Fit the dual O-ring into the adjacent recesses. Fit the smaller O-ring into the recess near the tip of the injector.
8. Apply a small amount of lightweight oil into the injector port on the induction module. Slide the injector into the port, making sure the plug-in connector at the outer end is facing toward the outside of the module. Attach the saved clip and retainer screw to the outer end of the injector. Attach the sensor wire to the plug-in connector on the injector.
9. Position the gas tank above the injection module. Reattach the plug-in wire connectors near the steering head. Reconnect the front and rear check-valve body assemblies at the underside of the gas tank. Reconnect the vapor valve line at the right side of the tank.
Secure the gas tank to the mount at the steering head with the saved bolt.
10. Reattach the rider’s seat and tighten the mounting bolts. Connect the wire to the back of the horn and mount the horn. Reattach the air cleaner cover.