Rajan Wilcox
Disconnecting the fuel line from a 2009 Harley Street Glide can be a tricky task. Before beginning, it is important to relieve the pressure in the fuel tank by opening the gas cap, removing the fuel pump fuse, and then starting the bike and letting it stall. Once this is done, the fuel line can be disconnected. There are a few different methods to do this, including using a siphon pump to drain the fuel tank or disconnecting the fuel line from the fuel rail. Some Harley models may also have quick-disconnect fuel lines, which can be disconnected by pushing the bung collars up, inserting the fuel lines into the bungs, and then pulling the collars down to lock the connections. It is important to note that some Harley models may have different methods of disconnecting the fuel line, so it is recommended to refer to the specific model's service manual for detailed instructions.
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What You'll Learn
Disconnecting the fuel line from the tank
Before beginning, it is recommended to refer to the official service manual for your Harley Street Glide, as it will provide specific instructions and illustrations tailored to your motorcycle. Additionally, consider watching YouTube videos created by experienced mechanics or Harley-Davidson enthusiasts, as they can offer visual guidance and valuable tips.
Firstly, it is important to relieve the pressure in the fuel system. This can be done by disconnecting the fuel pump power lead and turning the bike over several times. Alternatively, you can try starting the bike a few times after disconnecting the fuel pump connector to release any built-up pressure.
Now, let's move on to the fuel line itself. The first step is to locate the fuel line quick-connect fitting, which is usually found on the passenger side of the tank. Look for a silver cover with various wires and plugs; under this cover, you'll find the fuel line connection.
Once you've located the quick-connect fitting, use an 18mm open-end wrench to unscrew the fuel line from the tank. Be gentle, as the components may be tight but should not require excessive force to remove. You may also need to lift a sleeve or collar and pull out the hose, ensuring you guide it away from the tank to avoid any fuel spillage.
If your fuel line features O-rings, pay close attention to their condition. O-rings are prone to wear and tear and may need replacement. Consider purchasing an O-ring kit that includes various sizes to ensure a proper fit. Lubricating the O-rings with multi-purpose grease can also help prolong their lifespan and improve sealing.
Finally, always exercise caution when working with flammable liquids like gasoline. Ensure proper ventilation and avoid any open flames or sparks during the process. Have a fuel catch can or container ready to collect any residual fuel that may drain from the line or tank.
By following these steps and referring to the service manual and online resources, you should be able to successfully disconnect the fuel line from the tank of your 2009 Harley Street Glide. Remember to work carefully and take your time to avoid any potential issues.
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Disconnecting the fuel pump connector
First, safety must be a priority when working with any fuel system. Ensure the engine is turned off and the bike is securely parked on a level surface. Wear appropriate safety gear, including eye protection and gloves, to protect yourself from fuel spills and potential debris.
Now, to begin the process:
- Remove the fuel tank cover. There will be a silver cover underneath with various plugs, wires, and Torx screws. Remove these to access the inside of the tank.
- Locate the fuel pump. You should be able to see the tube quick connect on the pump from the passenger side of the bike.
- Before disconnecting the fuel line, it is important to relieve the pressure in the system. Open the gas cap and remove the fuel pump fuse. Then, attempt to start the bike a few times to release any remaining pressure.
- Squeeze the tabs on the quick connect and gently pull to remove the fuel line from the pump. Be cautious, as fuel may still spill or leak.
- Once the fuel line is disconnected, you can proceed with your maintenance or repair tasks.
It is important to note that working on a fuel system can be complex and requires mechanical aptitude. If you are uncomfortable with any part of the process, it is recommended to seek assistance from a qualified Harley-Davidson technician or a trusted mechanic. Additionally, always refer to the official Harley-Davidson service manual for detailed instructions specific to your motorcycle's make and model.
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Using a siphon pump to drain the tank
To disconnect the fuel line of a 2009 Harley Street Glide, you will need to drain the tank. Using a siphon pump is a safe and effective way to do this.
Firstly, you will need to purchase a siphon pump kit. These are available at any auto parts store or online for around $10. The kit will include a siphon pump and a length of tubing. You will also need a gas can or another closed container to siphon the fuel into.
Before you begin, relieve the pressure in the tank by opening the gas cap and removing the fuel pump fuse. Then, start the bike and let it stall.
Now, you can begin the siphoning process. Place the end of the tubing into the gas tank and the other end into the gas can. You may need to use the pump mechanism to create suction and start the flow of gas. Once the gas is flowing, the power of gravity should continue pulling gasoline from the tank and into the can. Monitor the flow to ensure it is steady and to check for air bubbles, which can impede the flow.
When you have nearly reached your desired amount of gas, stop the flow by raising the end of the tubing or the gas can to a level higher than the gas in the tank. This will cause any residual gas in the pump to drain back into the tank. Finally, remove the tubing from the tank and seal the gas can.
Some siphon pumps may need to be cleaned after use. Consult the instructions provided with your pump for more information.
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Locking the connections
To lock the connections of the fuel line, you will need to push the bung collars up, then insert the fuel lines into the bungs, and finally, pull the collars down.
Before you begin, it is important to relieve the pressure in the fuel tank. To do this, open the gas cap, take out the fuel pump fuse, and start the bike to let it stall.
Now, to lock the connections:
Step 1: Push the Bung Collars Up
Gently push the bung collars upwards. This will loosen the connection and allow you to insert the fuel lines.
Step 2: Insert the Fuel Lines
With the bung collars pushed up, carefully insert the fuel lines into the bungs. Ensure that the lines are firmly seated within the bungs.
Step 3: Pull the Collars Down
Once the fuel lines are securely in place, pull the collars back down. This action will lock the connections in place, ensuring a tight and secure fit.
Troubleshooting:
If you encounter any issues with leakage, it may be due to the O-rings. Check the O-rings for any damage or deterioration and consider using an O-ring repair kit to replace them. Additionally, ensure that the connections are properly seated and locked by following the steps outlined above.
It is recommended to refer to the Harley-Davidson service manual and parts book for additional guidance and diagrams. Furthermore, consider seeking advice from Harley-Davidson customer support or consulting with a qualified mechanic if you have any concerns or difficulties during the process.
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Using an O-ring kit to stop leaks
To stop leaks using an O-ring kit, there are several steps you can take to ensure proper installation and maintenance. Firstly, it is crucial to select the right O-ring material for your specific application. Factors such as temperature, pressure, chemicals, and mechanical stress should be considered when choosing the material. For example, chemical compatibility is necessary to prevent deterioration and leaks. O-rings are available in various materials, including Buna-N, Viton, silicone, and EPDM.
Once you have selected the appropriate O-ring material, precise sizing is essential. Measure the thickness or cross-section, the inner diameter, and the outer diameter of the O-ring to ensure a proper fit. Improper sizing can lead to leaks, as pressurised gases or liquids can travel through the parts if there is a loose fit. Therefore, it is crucial to refer to industry standards, such as the AS568 standard published by the Society of Automotive Engineers (SAE), to determine the correct O-ring size for your specific application.
Before installing the O-ring, it is important to inspect it for any defects, dirt, or damage. Clean the O-ring and the contact surfaces thoroughly to prevent surface contaminants from compromising the seal. Additionally, ensure that the O-ring gland and surface area are free of debris, dust, or other contaminants. Proper surface preparation helps to create a tight seal and prevent leaks.
When installing the O-ring, follow the manufacturer's instructions and ensure correct placement. O-rings should be positioned within a designated groove on the surface area to prevent dislodgement or damage during operation. Proper positioning also helps distribute sealing pressure evenly, minimising the risk of premature seal failure. Additionally, consider using a compatible lubricant on the O-ring and mating surfaces to improve sealing effectiveness and further prevent leaks.
By following these steps and paying attention to material selection, sizing, installation, and lubrication, you can effectively use an O-ring kit to stop leaks and maintain the integrity of your mechanical systems.
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Frequently asked questions
First, remove the tank cover, then the silver cover underneath it. Unhook the wires and plugs, and remove the 10 torx screws holding the cover in place. Once removed, you can see the tube's quick connect on the pump.
You will need a rebuild kit and some pick tools. You can also use a 9/32 deep well socket, 1/4 drive, or a dental pick to remove the O-ring.
To relieve the pressure, open the gas cap, remove the fuel pump fuse, then start the bike and let it stall.
Push the fuel line towards the fuel rail, pull and hold the retainer sleeve, then remove the fuel line.
Try the O-ring change and reseating. You can also grease the male end and plug it in and out a couple of times to lube and soften the O-ring.
