EFI RACE FUELER - Harley
Contents
1. 5of52. 7 Race Fueler Box 1 See Figure 7 The race fueler box is powered when the ignition key is turned to ON All three LEDs 2 will flash rapidly together for about one second This indicates that J03993 the race fueler box has power and that all three LEDs are operating 2 The race fueler box will then enter the monitor mode waiting for the engine to start running During monitor mode the center yellow LED will flash about twice per second 3 When the engine is first started the monitor mode will track each engine revolution and flash the two outer red and green LEDs Both the red and green LEDs should be flashing during this period if not turn off the engine and check the connections to the fuel injector 4 Monitor mode will be active while the engine stabilizes for the first 100 revolutions After that time the race fueler box will switch into run mode and the LEDs will no longer flash Run Mode Operation In the run mode the race fueler box is fully operational and may be adjusted by the user During the run mode only one LED will be active at a time and that LED will indicate which RPM range is active e Red Low RPM range e Yellow Mid RPM range e Green High RPM range Adjust RPM Ranges NOTES Ground yourself to the motorcycle by touching a metal portion of the vehicle before adjusting the Fueler potentiometers For example touch battery ground or the engine cases Solid state electronic com
3. the wires facing down The connections from the race fueler box will connect to each fuel injector and harness 4 Determine best routing for the race fueler box wires between the induction module and mounting location This will vary depending on motorcycle model 5 Attach hook and loop strip 2 to back of race fueler box and attach box with wires down to desired location near fuse box or in front of battery etc Do not mount to bat tery NOTE Connect black gnd lead to ground only If black lead is con nected to positive side of battery the EFI race fueler box will fail J03993 aani cpi LABLE E ET sian WITH WATEI activated SEALED sATTER ER remove sirip 2 HEE es for charging instructi 2 ae EA Earn seni CD otegaic YES 1 SUL EYES 1 NO TAC MS T GAN NESE FLAME NES i CEER KING 1 SEVERE BURNS NOT j EDIGAL O m HELP FAST 1 Race fueler box 2 Hook and loop strip 3 Black wire to ground Figure 4 Racer Fueler Box Typical 6 Attach black wire 3 on EFI race fueler box to ground 7 See Figure 5 Connect male yellow white lead 1 on fueler box to yellow green and white yellow injector wires 2 8 Connect female yellow white lead 3 on fueler box to front cylinder injector 9 Connect male green yellow lead 4 on fueler box to yellow green and green grey injector wires 5 10 Connect female yellow green lead 6 on fueler box to rear cylinder injector 1
4. 1 Keep wires out of the way of hot or moving parts with cable ties provided in kit WARNING Connect 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 12 Connect battery cables positive cable first 13 Verify initial power up and monitor mode and make initial RPM threshold fuel adjuster and accelerator enrichment settings See Tune Race Fueler Box topic 14 Return fuel tank to its original position and tighten fuel tank mounts to specification 2of5 is01211 1 Male connector front cylinder 5 Wiring harness rear connector light 2 Wiring harness front connector grey yellow white green yellow dark green wire wire 6 Male connector rear cylinder 3 Female connector front cylinder 7 Battery ground Do not attach to positive terminal 4 Female connector rear cylinder 8 Delphi injector body Figure 5 Race Fueler Box Connections Typical Install Race Fueler Box on VRSC Models 1 Remove airbox cover following the instructions in the Service Manual 2 Remove front side covers to gain access to wiring Remove horn to access fuel injector 1 Race fueler box 2 Wires at the bottom Figure 6 Fueler Box Wire Location 3 Route race fueler box wires from injector connectors to front of vehicle by inserting wire
5. MOTOR IN STRUCTI ON S EFI RACE FUELER PONR Kit Number PE Disconnect negative battery cable first If positive 32136 05A 32136 06A and 32136 07 cable should contact ground with negative cable con Models nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a These kits fit the following models r 2 Softail and Dyna models Disconnect battery cables negative cable first Table 1 Models i f VRSC models Remove right side cover and maxi fuse Kits Models Refer to MAXI FUSE in Service Manual 32136 05A 2001 2005 Twin Cam XL models Remove left side cover and maxi fuse Refer 2003 2006 VRSC to Maxi Fuse in Service Manual SAPPE UN ET Install Race Fueler Box on All EFI Models 32136 06A 2006 EFI Models 32136 07 2007 XL 1200 and XL WARNING 883 equipped with EFI 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 AWARNING death or serious injury 00330a 1 Loosen the fuel tank mounts and rotate tank forward to gain access to the fuel injector connectors located on the induction module The rider s safety depends 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 hav
6. e a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a isO1107 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 There are no Service Parts available with this kit INSTALLATION Prepare Motorcycle 1 Softail and Dyna models Remove seat according to the instructions in the Service Manual VRSC models Open the seat 1 Wire form Figure 1 Connector With Wire Form Awarnine 2 Remove fuel injector connector To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a a See Figure 1 Kit 32136 05A press wire form to remove connector b See Figure 2 Kit 32136 06A press gray release tab to remove connector c See Figure 3 Kit 32136 07 press release tabs to remove connector J03993 1 of 5 is03550 1 Male connector 2 Release tab Figure 2 Connector With One Release Tab is03551 1 Male connector 2 Release tab 2 Figure 3 Connector With Two Release Tabs 3 See Figure 4 Determine best location for mounting race fueler box 1 The location will vary depending on motor cycle model The race fueler box must be mounted with
7. ponents can be damaged by electro static discharge Ground yourself to the motorcycle before adjusting any of the potentiometers to avoid electrostatic damage 4of5 1 When dial is fully rotated counterclockwise to the silver dot adjustment is 10 2 When dial is fully rotated clockwise adjustment is 40 3 When dial is so direction indicator is pointing to the left parallel with the long edge of the EFI Race Fueler Box adjustment is 0 Figure 8 Potentiometer Dial NOTE If after adjustment the motorcycle does not start you can simply remove the Fueler and re connect the injectors The motorcycle will function in the same manner as before installation of the Race Fueler 1 See Figure 7 The race fueler box divides the engine rpm range into three segments which are selected by two potentiometer dial adjusters The RPM segment ranges are a Low to mid potentiometer dial adjuster 3 900 to 3500 RPM b Mid to high potentiometer dial adjuster 4 4500 to 7100 RPM J03993 2 The initial starting point threshold is set at a Low to mid potentiometer dial adjuster 2500 RPM b Mid to high potentiometer dial adjuster 5 000 RPM 3 With the engine idling less than 1550 RPM the red LED should be lit As the engine is revved to a higher RPM you will see the three LEDs light up in sequence as the RPM crosses each threshold Adjust Fuel Setting See Figure 8 Each of three RPM ranges has a cor
8. responding fuel adjuster LOW MID and HIGH Figure 7 Item 1 When the engine is running in a particular RPM range adjusting the fuel potentiometer dial adjuster for that range can change from 10 to 40 fuel The race fueler box uses a load based algorithm that tracks exactly how much fuel the PCM is calling for and changes the fuel percentage based on the poten tiometer dial adjuster setting The fuel adjustment is linear Adjust Accelerator Enrichment AE Fuel See Figure 7 Use the AE potentiometer dial adjustor 5 to eliminate stumble when opening the throttle The AE fuel is added only when the race fueler box detects a sudden increase in engine load and acts like an accelerator pump on a carbu retor The fuel is added over a brief period of time and the amount of fuel is adjusted from 0 to 100 by the AE poten tiometer dial adjuster Return Motorcycle to Service 1 Softail and Dyna models Install seat according to the instructions in the Service Manual 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 CAUTION When closing the seat make sure the ignition switch is in the FUEL position If the ignition switch is in any other position when the seat is closed the seat latch mechanism could be damaged 00196a 2 VRSC models Close and lock the seat
9. s under air box J03993 3 of 5 4 See Figure 6 Mount race fueler box 1 with wires facing down 2 in most accessible location using hook and loop strip NOTE Connect black gnd lead to ground only If black lead is con nected to positive side of battery the EFI race fueler box will fail 5 See Figure 5 Connect male yellow white lead 1 on fueler box to yellow green and white yellow injector wires 2 6 Connect female yellow white lead 3 on fueler box to front cylinder injector 7 Connect male green yellow lead 4 on fueler box to yellow green and green grey injector wires 5 8 Connect female yellow green lead 6 on fueler box to rear cylinder injector 9 Keep wires out of the way of hot or moving parts with cable ties provided in kit 10 Install maxi fuse and right side cover Refer to MAXI FUSE in Service Manual 11 Verify initial power up and monitor mode and make initial RPM threshold fuel adjuster and accelerator enrichment settings See Tune Race Fueler Box topic 12 Install airbox cover following the instructions of the Service Manual TUNE RACE FUELER BOX Initial Power Up and Monitor Mode Operation is01214 b Potentiometer dial adjuster low mid high range fuel LED indicators low mid high range Potentiometer dial adjuster low mid range rpm Potentiometer dial adjuster mid high range rpm Potentiometer dial adjuster accelerator pump output PON Figure
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