Changing Fuel Filters: A Guide For Harley Softail Owners

Changing the fuel filter on a Harley-Davidson Softail is an important service item. The fuel filter or strainer on a carbureted Harley-Davidson Softail is a component part of the fuel supply valve, which controls the flow of gas to the carburetor and strains out unwanted contaminants. Harley-Davidson recommends replacing the fuel filter at 25,000-mile intervals, but this may vary depending on your riding conditions and the types of fuel you have been using. Replacing the fuel filter typically takes around one hour and requires tools such as a wrench, a screwdriver, and a hand-operated vacuum pump. It is important to take your time and work carefully to avoid damaging any components.

Harley Fuel Filter Removal

Step 1: Prepare for the Procedure

Before starting, gather the necessary tools and parts, including a new fuel filter, gaskets, and cover bolts. Familiarize yourself with the fuel system and refer to your specific Harley model's service manual for additional instructions and safety precautions. Cover any painted parts to avoid accidental damage and use caution when handling fuel to prevent spills or injuries.

Step 2: Purge Fuel Pressure (for Fuel-Injected Models)

Remove the left saddlebag and side cover to access the fuse box. Open the fuse box and locate the fuel pump fuse. Depress the tab on the fuse box lid to open it, then remove the fuel pump fuse. Start the engine, which will stall within a few seconds due to the lack of fuel.

Step 3: Disconnect the Battery

Remove the fastener at the rear of the seat and slide the seat unit rearward to access the ECM (Electronic Control Module) plate. Disconnect the negative battery cable to prevent any electrical shorts or fire hazards while working on the fuel system.

Step 4: Remove the Fuel Tank Console

The fuel tank console is held in place with hex (Allen) fasteners. Remove the front and rear fasteners to detach the console from the tank. For pre-2008 models, there are two additional fasteners located under the fuel filler door. Place a soft towel on the rear fender and carefully lay the console onto it.

Step 5: Remove the Fuel Pump Assembly

This step varies depending on the model year of your Harley Softail. For pre-2008 models:

• Disconnect the fuel pump harness plug and fuel vapor vent line.
• Using a T20 Torx driver, remove the screws securing the canopy assembly to the fuel tank.
• Lift the canopy/fuel pump assembly slightly and cut the hose clamp securing the corrugated tube.
• Depress the black locking tab with a screwdriver to allow the pump to swing open.
• Now, lift the fuel pump assembly out of the tank.

For 2008 and newer models:

• Disconnect the fuel pump harness plug and fuel vapor vent line.
• Using a hammer and punch or a locking ring removal tool, tap the locking ring tabs in a counter-clockwise direction to free the locking ring.
• Lift the fuel filter assembly out of the tank and disconnect the quick-connect fuel lines running to the filter housing.
• Pull out the entire pump assembly, inspecting and replacing the corrugated lines if necessary.

Step 6: Remove the Old Fuel Filter

For pre-2008 models:

• Swing the wireform securing strap off of the filter body.
• Remove the hold-down tab from behind the filter.
• Cut the hose clamp off of the corrugated fuel line at the filter nipple and separate the filter from the pump assembly.

For 2008 and newer models:

• Remove the filter retaining clip by depressing the release tab and sliding the clip out of its groove.
• Separate the filter housing from the pump body.

Step 7: Install the New Fuel Filter

For pre-2008 models:

• Install a new o-ring(s) onto the new fuel filter before placing it into the fuel pump.
• Attach the corrugated fuel hose to the filter nipple and secure it with a new hose clamp. Ensure the filter hold-down tab engages properly.
• Slide the wireform securing strap over the filter body until it engages the slots in the filter bracket.

For 2008 and newer models:

• Install the new filter along with a new filter housing o-ring.
• Attach the filter housing to the pump body and secure it in place with the retaining clip.

Purging fuel pressure

To purge the fuel pressure on a Harley Davidson Softail, you will need to relieve the fuel pressure. This can be done by removing the grey connector on the top of the battery compartment, which should be black and grey. If there is only one black connector, as in some models, you can relieve the fuel pressure by taking out the fuse for the fuel pump and turning the engine over a few times.

Another method is to remove the fuel tank hose at the quick disconnect, which will only result in a few drops of fuel spilling. If you have a canbus model, you can disconnect the connector for the fuel pump, turn the ignition on, and start the bike. The engine will run for a few seconds and then die, purging the fuel pressure.

It is important to note that Harley Davidson recommends performing a fuel tank filter replacement at 25,000 miles, but this may vary depending on your riding conditions and fuel type.

Disconnecting the battery

Step 1: Remove the Seat

Locate and remove the fastener at the rear of the seat. Gently slide the seat unit rearward to detach it from the bike. For some Harley-Davidson models, you may need to remove the seat strap before removing the seat unit.

Step 2: Access the Battery

Underneath the seat, you will find the ECM (Engine Control Module) plate, which needs to be removed to access the battery. Use a T40 torx fastener to loosen and remove the ECM plate. If your motorcycle has a security system, carefully slide the antennae off the plate before removing it.

Step 3: Disconnect the Negative Battery Cable

With the ECM plate removed, you will now have access to the battery. Identify the negative (-) cable and carefully disconnect it. It is important to disconnect the negative cable first to avoid any potential sparks or short circuits.

Step 4: Reattach the ECM Plate

Once the negative cable is disconnected, you can proceed to reattach the ECM plate. Secure it in place using the T40 torx fastener. If you removed the antennae during Step 2, remember to slide it back onto the plate before reattaching it.

Step 5: Safety Precautions

Always exercise extreme caution when working with electrical components. Ensure that you have properly identified the negative battery cable and that there are no signs of damage or corrosion on the battery terminals. If there is any visible damage or leakage, do not proceed, and consult a qualified technician.

Step 6: Work Environment

It is advisable to wear protective gear, such as gloves and eye protection, when handling batteries. Ensure that you are working in a well-ventilated area and that you do not leave any tools or loose items on top of the motorcycle, as they may fall and cause damage.

Step 7: Post-Maintenance

After completing the fuel filter replacement, remember to reconnect the negative battery cable securely. Check that all connections are tight and free of debris. Conduct a final inspection of your work before starting the engine and testing the motorcycle.

Removing the fuel tank console

The fuel tank console must be removed to access the fuel pump assembly. The console is held in place on the fuel tank with hex (Allen) fasteners. To begin, remove the front and rear fasteners to free the console from the tank. For pre-2008 models, there are an additional two fasteners under the fuel filler door.

Place a soft towel on the rear fender. Remove the fuel cap and carefully lay the console onto the towel. This will allow for the pump assembly to be removed without disassembling the console.

Step-by-step guide to removing the fuel tank console:

• Remove the fasteners: Using the correct size Allen key, remove the front and rear hex fasteners from the fuel tank, securing the console in place.
• Place a towel on the rear fender: This will protect the fender from any potential scratches when placing the console on it.
• Remove the fuel cap: With the fasteners removed, carefully lift and remove the fuel cap from the tank.
• Lay the console onto the towel: Gently place the console onto the towel, ensuring it is secure and won't slide off.
• Access the pump assembly: With the console removed, you will now have access to the fuel pump assembly for further maintenance or repairs.

Reassembly

Firstly, replace any fuel lines and hose clamps as necessary before placing the fuel pump assembly back into the tank. Harley-Davidson recommends using a new canopy gasket (pre-2008 models) or locking ring gasket (2008+ models).

For pre-2008 models, the pump should pivot once it is inside the tank to engage the locking mechanism. Install 10 new canopy bolts and torque to 18-24 in/lbs in a criss-cross pattern.

On 2008+ models, using downward pressure, start the locking ring into the fuel tank. Using a hammer and blunt object, drive the locking ring in a clockwise direction until the tabs are seated against their stops.

Reconnect the fuel pump harness plug and fuel vapour vent line. Install the console onto the tank and torque the fasteners to 36-60 in/lbs. Install the fuel cap and close the fuel filler door.

Reconnect the battery cable(s) before installing the ECM plate and antennae (if applicable). Install the fuel pump fuse. Install the seat unit, side cover, and saddle bag.

Motorcycles equipped with a security system often require the system to be reset after the battery has been disconnected. See your service manual for details.

Frequently asked questions