Harley Davidson Touring: How to Remove Gas Tank
- Step 1 – Purge fuel system Models equipped with fuel-injection have a pressurized fuel system that must be purged prior to removing the fuel tank. ...
- Step 2 – Disconnect battery ...
- Step 3 – Remove fuel tank console ...
- Step 4 – Disconnect the fuel tank ...
- Step 5 – Unbolt the fuel tank ...
- Step 6 – Re-installation ...
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How to remove the front tank mount caps?
Remove the rubber tank mount caps at the front of the fuel tank to reveal the mounting fasteners. Using a 1/2" socket or T40 Torx driver , remove the (2) front tank mounting bolts.
Why disconnect battery from fuel tank?
Since removing the fuel tank often requires working with fuel, it is best to disconnect the battery to avoid any electrical shorts that could start a fire.
How to open a fuel pump fuse box?
Depress the latch on the bottom of the fuse box lid to swing the lid open. Using the diagram on the fuse box lid, remove the fuel pump fuse.
What screws are under the fuel door?
Depending on the year and model, there may be several Hex (Allen) screws under the fuel door that require removal before the console can be removed.
How to avoid disconnecting gauge wiring?
Place a soft towel on the rear fender and lay the console onto the towel to avoid disconnecting any gauge wiring.
Where is the crossover line on a fuel injector?
For fuel-injected models equipped with a five gallon fuel tank, the crossover fuel line at the front of the tank must be disconnected. Disconnect the crossover line and allow escaping fuel to drain into your catch can.
Can you lift a fuel tank off a bike?
With all fasteners, fuel lines, and electrical wiring disconnected, the fuel tank can be gently lifted from the bike and set in a safe place.
What side of the fuel tank is the fuel valve on a shovelhead?
There is typically a fuel valve on the left side fuel tank and a fuel crossover line between the two tanks.
Can you drain a tank from a fuel valve?
Tanks can be drained from the fuel valve but they drain quicker from the fuel crossover. When draining from the crossover you should use line clamps and rubber plugs. There is more than one way to accomplish draining. Do what works best for you.
Should fuel lines be replaced?
If fuel lines are in question, they should be replaced during reassembly. Fuel tank grommets should also be replaced. If you are considering upgrading your fuel valve, now is the time. There are many different reasons your two piece fuel tanks may need to be removed.
Does a Harley Davidson fuel tank need to be drained?
The fuel crossover line will equalize fuel level between both side tanks. Harley Davidson fuel tanks should always be drained before removing. If fuel is left inside the tanks, the tanks will be heavier and harder to handle. Tanks can be drained from the fuel valve but they drain quicker from the fuel crossover.
How to remove fuel tank on motorcycle?
Have a safe spot ready for your fuel tank. Carefully lift up and back as you pull the fuel tank off of the motorcycle’s frame. Do not lift the tank into your bars, or controls.
What do you need to disconnect a fuel line crossover?
Line clamps are helpful when disconnecting your fuel line crossover. Also, you will need to have a couple of rubber plugs handy. You need to be prepared, and take your time when draining the fuel tank. You may lose some fuel, but make it minimal if you can. Remove your tank hardware in the front and rear of the tank.
Can you disconnect a battery and unplug the fuel line?
Now you can disconnect your battery and unplug your fuel feed line. When removing your dash, it is important to have a second set of hands. Have your helper hold the dash, safely, on its side while you unplug your dash. If uncertain, it is always a good idea to take a photo, for reference, for reassembly.
Where is the vent hose on a gas tank?
8. At the front of the tank there is a vent hose. Remove it.
How to remove a hose clamp?
Stick a small screwdriver in the portion of the clamp that sticks up, and work it back and forth until you can get the clamp off (or loose). Now you should be able to stick the screw driver between the end of the hose, and the base of the pump, and pry the hose to the point it can be removed by hand.
How to loosen a quick release?
Using a wrench, start loosening the quick release. The ribbed fuel line, inside the tank, is attached to the quick release. It will turn as you are loosening the quick release. You might want to stick your hand inside the tank, and help it turn, so it doesn’t get tangled and break off.
Where is the rubber washer on a rear tank bolt?
20. At the spot where you removed the rear tank bolt, there is a rubber washer. Be very careful not to lose it. That’s something you will need when during reassembly.
Can you remove the pump plate?
At this point, you still cannot remove the pump plate and pump assembly. The pump assembly has a long, black plastic "arm", with an elbow. That elbow, while in the tank, is bent at a 90° angle. It cannot be removed while at this angle. The picture below shows how it sits while inside the tank.
Can you pull a pump out of a tank?
26. You can now pull the pump assemble almost completely out of the tank. Unfortunately, there is a long wire with a float on the end, preventing you from removing it completely.
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How to change a gas tank on a bike?
1. Start by draining the fuel tank of any remaining gas. Disconnect the fuel line and remove the tank from your bike. Remove the petcock and plug with rubber tubing and heavy duct tape, or anything else that can be used as a plug. Do not use any tubing or your original petcock valve that will be reused. 2.
How to clean rust from gas tank?
The easiest way to clean a gas tank of rust and other contaminants is with Muriatic Acid*. Commonly used for pool cleaning and cement etching, this acid can be found at most pool supply stores or any garage meth lab. However I’d stick with the store and avoid hanging out near crazed meth lab tweakers! Avoid contact with this very corrosive acid by wearing heavy rubber gloves and protective eyewear at minimum.
How to clean a gas tank with Muriatic acid?
2. Pre-clean the tank with a 1/2 gallon of gasoline. Cap the tank and agitate by rocking the tank. Dispose of fuel in a proper container. 3. Fill 1/2 the tank with hot water. Now add approximately 1/2 a gallon of Muriatic Acid* and top up the remaining with more hot water.
Can you use WD-40 to clean a car?
Step away from that can of WD-40! Use the right product for the job. You wouldn’t wash your car or Harley with a harsh solvent, so don’t use penetrating oil in place of lubricant or cleaner. WD-40 is a water dispersing penetrating oil originally designed to repel water. Almost 60% of this solution is an aromatic corrosive solvent designed to penetrate metals, with a suspended paraffin lubricant designed to remain upon evaporation. There are rumors that WD-40 will actually eat away at certain metals and rubber, but the fact is that WD-40 is NOT designed to clean fuel tanks or lubricate while in storage.
Can you clean a Harley fuel tank?
Harley fuel tank cleaning (or other motorcycle tanks) can be a simple task given you follow some basic steps. Rust or sludge can be very damaging to your fuel system and should not be left untreated. Severe cases of rust can often lead to the eventual failure (leaking) of the tank, so seek professional help if you believe that your fuel tank is in such bad condition.
Step 1 – Purge Fuel System
Step 2 – Disconnect Battery
- Since removing the fuel tank often requires working with fuel, it is best to disconnect the battery to avoid any electrical shorts that could start a fire. 1. Remove the fastener at the rear of the passenger seat and slide the seat unit rearwards to remove it from the bike. If your bike has a seat strap, remove one of the strap bolts on either side to free the strap before removing the seat. 2. …
Step 3 – Remove Fuel Tank Console
- If possible, it is best to begin this procedure with a fuel tank that is nearly empty; otherwise, you may have to drain several gallons of gas out of the tank in the process. With the battery disconnected, proceed with removal of the fuel tank console. 1. Begin by removing the front and rear fasteners holding the console assembly to the tank. 2. Open the fuel door and remove the fil…
Step 4 – Disconnect The Fuel Tank
- Disconnect the pump wiring harness plug.
- On the left underside of the tank, disconnect the fuel level sensor plug.
Step 5 – Unbolt The Fuel Tank
- Remove the rubber tank mount caps at the front of the fuel tank to reveal the mounting fasteners. Using a 1/2" socket or T40 Torx driver, remove the (2) front tank mounting bolts.
- At the rear of the tank, slide the plastic trim piece off of the tank bracket before removing the (2) fasteners with either a 1/2" socket or T40 Torx driver.
- With all fasteners, fuel lines, and electrical wiring disconnected, the fuel tank can be gently lif…
- Remove the rubber tank mount caps at the front of the fuel tank to reveal the mounting fasteners. Using a 1/2" socket or T40 Torx driver, remove the (2) front tank mounting bolts.
- At the rear of the tank, slide the plastic trim piece off of the tank bracket before removing the (2) fasteners with either a 1/2" socket or T40 Torx driver.
- With all fasteners, fuel lines, and electrical wiring disconnected, the fuel tank can be gently lifted from the bike and set in a safe place.
Step 6 – Re-Installation
- Installation of the fuel tank is the reverse of the procedure outline above. 1. Set the fuel tank onto the bike and install the front and rear fastening bolts. Torque to 15-20 ft/lbs. Be sure to install the plastic trim piece and rubber mount covers (if applicable). 2. Reconnect the fuel supply line quick release. 3. Reconnect the fuel tank level harness plug as well as the fuel pump harness plug. 4. F…
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