1. Safety First:
Make sure the motorcycle is parked on a flat surface and the engine has had sufficient time to cool down to prevent burns. Disconnect the battery to ensure no electrical interference.
2. Locate the Engine Temperature Sensor (ETS):
The ETS is usually located near the top of the engine, or on the cylinder head. On some Ultra Classic models, it might be found below the air cleaner cover.
3. Remove the Fuel Tank:
To access the ETS, you may need to remove the fuel tank. Consult your motorcycle's service manual for specific instructions on removing the tank.
4. Disconnect Electrical Connectors:
Locate the electrical connector attached to the ETS. Disconnect the connector by gently squeezing the retaining clip and pulling it off.
5. Remove the Sensor:
Using the appropriate wrench or socket (usually 10mm or 12mm), loosen and remove the nut or bolt that secures the sensor. Be careful not to drop the sensor or lose any parts.
6. Clean the Sensor Well:
Before installing the new sensor, clean the sensor well and threads with a wire brush and compressed air. Make sure the sealing surface is debris-free.
7. Install the New Sensor:
Apply a sealant to the threads of the new sensor to prevent leaks. Carefully screw in the sensor until it is snug and makes contact with the engine surface.
8. Reconnect Electrical Connector:
Reconnect the electrical connector by aligning it with the sensor's connector and pushing it in until it clips into place.
9. Reinstall the Fuel Tank:
Carefully reinstall the fuel tank and reconnect the fuel line if removed during the process.
10. Test the Sensor:
Start the motorcycle and let it idle for a few minutes to allow the engine to warm up. Use a multimeter or check engine lights to verify the sensor's function.
11. Secure Fuel Lines and Hoses:
Double-check that all fuel lines and hoses are properly secured and there are no leaks.
12. Road Test:
Take the motorcycle for a test ride to ensure the temperature readings are accurate.
Note: It's essential to refer to the service manual for your specific Harley-Davidson Ultra Classic model for detailed instructions, bolt sizes, and torque specifications. If you're not confident in performing this task, it's best to have the work done by a qualified mechanic.
