SPORTSTER
XR-1200
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
TOOLS NEEDED
- T40 Torx
- 7/16” Socket
- 3/8 Ratchet
- #1 Phillips Screw Driver
2009 XR-1200
Fuel Injected Models
INSTALLATION INSTRUCTIONS FOR P/N 61005A
INTRODUCTION: Congratulations on your purchase of the Fuelpak
Fuel Management System for your fuel injected Harley-Davidson XR1200 motorcycle. Please take the time to read the entire instruction
manual before attempting to install. DO NOT adjust the Fuelpak until
you have thoroughly read the instruction manual and the unit is fully
installed. If you have questions, please call (562) 921-0071.
SUMMARY: To achieve the optimum performance from your
application, it is recommended that you install a high performance
air filter in conjunction with this unit. The Fuelpak will be installed
between the factory wiring harness and the Electronic Control Unit (ECU).
PLEASE NOTE: FUELPAK RECOMMENDS A HIGH PERFORMANCE AIR FILTER.
1.
Be sure the main and handlebar switches are in the off position
during the installation process. Failure to do this will cause the
“check engine” light to be set.
2.
Remove rider seat by pressing in on tabs located under seat at
rear of fuel tank.
3.
Remove passenger seat by removing bolt (7/16” hex head) from
under tail section.
4.
INSTALLATION INSTRUCTIONS
FUEL INJECTION MANAGEMENT SYSTEM
NOTICE:ᾨ
Fuelpak is intended for racing use only, and
is not legal for sale or use in California on
pollution-controlled vehicles.
Remove five (5) bolts (7/16” hex head) holding seat pan to
frame. Remove seat pan. (Fig 1)
5.
Remove three (3) bolts (T40 torx head) securing seat sub frame.
(Fig 2) (We recommend loosening all other torx head bolts on
sub frame to aid in seat sub frame removal.)
6.
Remove seat sub frame and open left side cover.
7.
Disconnect the factory connector from the ECU by pressing the
latch lever and pulling. Often, this connector can be very secure.
8.
The Fuelpak has two connectors, one black and one grey.
Connect the Fuelpak black connector to the factory harness.
Connect the Fuelpak grey connector to the factory ECU. Be sure
both grey connectors are fully seated and latched.
9.
Route Fuelpak unit through opening between the frame and oil
tank to left side of motorcycle. (May need to remove Fuelpak lid.)
10. Arrange Fuelpak connector and factory wiring as shown. (Fig
3&4) The Fuelpak black connector must be next to the ECM. Reinstall seat sub frame. (Be sure to tighten all bolts on sub frame.)
11. Re-install seat pan. Re-install rider and passenger seats.
12. You are now ready to set-up your Fuelpak.
HOW IT WORKS
2. Turn on main power and handlebar switches, but do not start engine. Fuelpak display should
light up, if not, turn power off and verify the connectors are fully seated.
3. Refer to Fuelpak Setting Reference to locate the Setting Values specific to your bike and exhaust
system. If you do not find your setting, visit fuelpakfi.com or call tech support at (562) 921-0071.
ENTERING VALUES
FUEL INJECTION MANAGEMENT SYSTEM
1. Remove Fuelpak clear case cover by removing all four screws, save hardware.
4. Starting with mode 1 selected, press the value (+) or the value (-) buttons to input the correct
value as indicated in your Setting Value. After entering your first value, press the mode select
button to move to mode 2 and enter the value. Continue until you have entered the value for
each of the first 18 mode positions. Each time the value (+) is pressed; the value increases by one
number. Each time the value (-) is pressed; the value decreases by one number. (Please refer to the
“How It Works” section directly above if you have questions about this step.
5. As the next procedure, after you have entered in your values for the first 18 modes, press the
mode select button to move to mode 19. Fully twist open the throttle and return to idle position
to calibrate the Fuelpak to your bike.
6. By pressing the mode select button twice, move to mode 21 and verify that it reads “0” with the
throttle closed, “50” at approximately half-throttle and “99” when fully opened; if not, repeat step
21. Do not proceed to step 23 until mode 21 is verified.
7. Enter any other mode values as required for your application.
8. Turn power off, wait one second then turn power back on. Verify all modes then turn power off.
9. You are now ready to ride.
IN THE EVENT OF A MALFUNCTION, PLEASE CHECK THE FOLLOWING
1. 2. 3. Turn off main and handlebar switches then verify all connectors are fully seated.
Be sure setting values are correct for your application.
Verify throttle calibration, step 5 in Entering Values.
4.
5. 6. Check harness for cuts, scrapes or abrasions.
Make sure the battery is fully charged and the charging system is operating correctly.
Calltechnical support at (562) 921-0071
WARRANTY INFORMATION
WARRANTY: Your Fuelpak unit is warranted against defects
in materials and workmanship for the period of 90 days from
the original retail purchase. In the event of an alleged defect
in material or workmanship, Fuelpak’s responsibility is strictly
limited to repair or replace the defective product. Fuelpak
shall not be responsible for (a) labor, transportation, or other
incidental charges; (b) consequential or other damages
incurred by use of any product. Fuelpak offers no other
warranty beyond this limited warranty. This limited warranty
does not apply to products which have been (a) modified
or altered in any way; (b) subjected to adverse conditions,
such as misuse, neglect, accident, improper installation or
adjustment, contaminants, corrosion, or faulty repair; or (c) used
in applications other than those recommended by Fuelpak. To
initiate a warranty process, the consumer must first call technical
support to receive a return authorization number. The product
must be returned to Fuelpak complete with a dated receipt and
a return authorization number.
Fuelpak
Attn: Warranty Claims
13861 Rosecrans Avenue
Santa Fe Springs, CA 90670
(562) 921-0071
P/N 51793 061509