Ameer Randolph
Harley fuel tanks are connected by a small pair of hoses, and the tanks have crossover nipples that connect the two. The crossover hose should be clamped on both sides of the center in front of the frame. The fuel line, fuel filters, and petcocks are important to keep the fuel flowing in your Harley. They can become clogged over time, so it is important to clean or replace them.
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What You'll Learn
The crossover nipples and clamps connect the two tanks
The crossover line at the bottom front has Oetiker clamps on each side. There is a vent line that connects the two sides of the tank, passing under the dashboard base. This upper vent allows air to pass between the tanks so fuel can flow from one side to the other.
When removing the fuel tank, clamping the two hoses with two hose clamp pliers can reduce the potential for gas spills. To replace the stock hose, clamp the crossover hose on both sides of the centre in front of the frame. Cut the hose and drain the fuel.
The two tanks are connected by a small pair of hoses, and filling both tanks is recommended. The left tank should be filled first, then the right, as the connecting hoses can allow enough fuel transfer to cause the left tank to overflow.
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A vent hose balances air pressure between the tanks
The two sides of a Harley fuel tank are connected, and a vent hose is necessary to balance the air pressure between the tanks. This is because the vent hose handles only air/vapour, allowing air to pass between the tanks so that fuel can flow from one side to the other.
A Harley fuel tank has crossover nipples on the bottom of the left side tank and the top of the tank near the cap, which connect the two tanks. The clamps are definitely on the bottom, but some users are unsure about clamps on the top. The top crossover is a point of confusion for some Harley owners, who are unsure whether it is a fuel line or just a vent hose.
A vent hose is necessary to balance the air pressure between the tanks. If the vent hose is broken, it can lead to a pressure build-up in the tank. This is because the vent hose allows air to escape from the tank, and if it is blocked or plugged, the air cannot escape, leading to a pressure build-up. A one-way valve in the hose can also cause pressure build-up as it allows pressure out but not in.
To fix a pressure build-up issue, some Harley owners have connected a short hose to the nipple of each tank, hooked them into a tee fitting, and then ran a hose to the vapor valve. This has resolved the pressure issue.
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Filling both tanks is important to avoid overflow
The Harley fuel tank has two sides connected by a small pair of crossover hoses, with clamps at the bottom and potentially at the top as well. The top crossover hose is a vent line that allows air to pass between the tanks so that fuel can flow from one side to the other.
To further prevent overflow, it is important to ensure that the crossover hoses are not clogged. Additionally, when removing the fuel tank, clamping the two hoses with hose clamp pliers can reduce the potential for gas spills.
It is worth noting that some newer Harley models may only fill on the right side, with the left side being a non-removable gas gauge. However, for older models with two tanks, filling both tanks is crucial to prevent overflow.
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Clamping the crossover hose makes tank removal easier
The Harley-Davidson fuel tank has crossover nipples that connect the two tanks. The bottom of the left-side tank and the top of the tank near the cap have these crossover nipples. The clamps are on the bottom, but some users are unsure about clamps on the top. The right-side tank has the same crossover nipples on the top and bottom, with an extra nipple on the bottom.
When removing the fuel tank, clamping the two hoses with two hose clamp pliers can make the process easier and reduce the potential for gas spills. It is recommended to clamp the crossover hose on both sides of the center, in front of the frame. A catch pan should be placed underneath to catch any spilled fuel. The stock hose can then be removed, and the fuel tank can be placed on a workbench for further work.
One method to reduce fuel spillage is to use two small pairs of needle-nose vice grips to clamp the line on both ends close to the nipples. The center section of the hose can then be cut away, and the tank can be removed. The fuel in the center section of the line can be drained into a bucket, and any remaining fuel can be soaked up with a rag.
Another approach to make tank removal easier is to use a siphon to remove as much gas as possible before beginning the process. This can be done by raising the front of the bike so that all the fuel runs to the back of the tank. Once the tank is drained, the crossover hose can be clamped and removed, and the tank can be pulled off.
By clamping the crossover hose and taking the necessary precautions to minimize fuel spills, Harley-Davidson owners can more easily remove the fuel tank for maintenance or modifications.
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The fuel gauge control unit connects to the line joining both sides
The Harley-Davidson motorcycle has two tanks that are connected by a small pair of hoses. The bottom of the left side tank and the top of the tank near the cap have crossover nipples that connect the two tanks. There are clamps on the bottom, but some users do not recall having them on the top. The top crossover is a vent hose that balances the air pressure between the tanks. It allows air to pass between the tanks so that fuel can flow from one side to the other.
To ensure seamless fuel delivery and optimal engine performance, it is essential to maintain the fuel lines, fuel filters, and petcocks in good working order. Clogged fuel lines, filters, and petcocks can lead to degraded fuel and debris accumulation, affecting the performance of your Harley. Regular cleaning or replacement of these parts is recommended to prevent issues and maintain the health of your engine.
Additionally, when removing the fuel tank, it is important to clamp the two hoses with hose clamp pliers to reduce the potential for gas spills. This process can be challenging, and it is recommended to refer to detailed guides and seek appropriate tools to ensure a successful tank removal and installation.
Overall, the fuel gauge control unit in a Harley-Davidson motorcycle connects to the line joining both sides of the fuel tank, providing information on the fuel level, and it is crucial to maintain the fuel delivery system and take necessary precautions during fuel tank removal and installation.
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Frequently asked questions
There are two tanks connected by a small pair of hoses. The bottom of the left side tank and the top of the tank near the cap have the crossover nipples that connect the two tanks.
Fill the left tank first while standing the bike straight up, then set it on the kickstand and fill the right tank. The bleed-over/crossover hoses work slowly, so you need to fill both tanks separately. Be careful not to overfill the left tank as the connecting hoses can allow enough fuel transfer to cause the left tank to overflow.
Fuel lines, fuel filters, and petcocks are important to keep in working order to ensure seamless fuel delivery. They can become clogged over time due to fuel degradation and debris, so they need to be cleaned or replaced regularly.
