Harley Davidson Touring: Replacing Fuel Filter, Step-By-Step Guide

Harley-Davidson recommends replacing your fuel filter every 25,000 miles. However, some owners have gone up to 100,000 miles without changing it, while others have noticed a dirty filter at just 10,000 miles. A clogged filter can cause engine performance issues, so regular replacement is essential. This article will outline the steps to replace the fuel filter on a Harley-Davidson touring bike.

Purging the fuel system

Before starting any work on the fuel system, it is important to relieve the fuel pressure. The fuel pump can maintain pressure for days after the bike has been turned off, so purging the system will prevent accidental fuel spray.

First, remove the left saddle bag and side cover. The cover can simply be pulled straight off to reveal the fuse box. Open the fuse box by depressing the tab at the bottom of the lid and, following the fuse diagram, remove the fuel pump fuse. With the fuse removed, start the engine to relieve the fuel pressure. The engine will stall within a few seconds once it runs out of fuel.

Next, disconnect the battery to prevent the possibility of an electrical short and potential fire hazard. Disconnecting the battery is always recommended when working with fuel system components. Remove the fastener at the rear of the seat and slide the seat unit rearward to free it from the bike. Some models may require the seat strap to be removed before removing the seat unit.

Under the seat is the ECM plate, which must be removed to access the battery. Remove the T40 torx fastener and set the ECM plate aside. If your bike has a security system, be sure to slide the antennae off the plate before removing it. With the battery accessible, disconnect the negative (-) cable.

Optional) Draining and removing the fuel tank

Although it is not required, some owners prefer to drain the fuel tank and remove it from the bike. This can make it easier to manipulate the tank internals when changing the fuel filter.

Removing the tank console and gauges

If you are changing the fuel filter with the tank mounted on the bike, you will need to remove the tank console and gauges. Remove the fastening screws securing the console to the fuel tank. Depending on the model, you may need to remove the seat to do this. With the console free from the tank, disconnect the gauges and set the console assembly aside.

Disconnecting the battery

To disconnect the battery, first, remove the fastener at the rear of the seat and slide the seat unit rearward to free it from the bike. Some models may require the seat strap to be removed before the seat unit can be taken out.

Next, locate the ECM plate under the seat and remove it to access the battery. For bikes equipped with a security system, remember to slide the antennae off the plate before removing it.

With the battery exposed, disconnect the negative (-) cable. Now it is safe to proceed with the next steps in changing the fuel filter.

When the fuel filter replacement is complete, remember to reconnect the battery cable(s) before reinstalling the ECM plate and antennae (if applicable). Reinstalling the seat unit, side cover, and saddle bag will finalise the process.

Removing the fuel tank

The first step in changing the fuel filter on a Harley Davidson Touring bike is to relieve the fuel system of pressure. This is done by accessing and removing the fuel pump fuse located in the fuse box below the left side of the seat assembly. With the fuse removed, crank the engine to relieve the fuel pressure. The engine will run for a few seconds before it loses fuel pressure and stalls.

Next, disconnect the battery to prevent any possibility of an electrical short and potential fire hazard while working with fuel.

While not necessary, some owners prefer to drain the fuel tank and remove it from the bike for easier manipulation of the tank internals. If you choose to do this, refer to the instructions in "How to Remove Fuel Tank" for guidance.

If you are changing the fuel filter with the tank mounted on the bike, proceed to remove the console and gauges. Remove the fastening screws securing the console to the fuel tank. Depending on the model, you may need to remove the seat first. With the console free, disconnect the gauges and set the console assembly aside.

With the tank top plate accessible, disconnect the fuel pump wiring harness connector and vent tube. Remove the screws from the top plate and lift it up at an angle to allow the hard vent tube to clear the fuel tank. Depress the tab on the fuel pump wiring harness with a small screwdriver to release it from the plate and set the plate and plate gasket aside.

Removing the tank console and gauges

To remove the tank console and gauges, you will need to remove the fastening screws that secure the console to the fuel tank. Depending on the model of your Harley Davidson Touring bike, you may need to remove the seat to access these screws. Once the screws are removed, carefully disconnect the gauges and set the console assembly aside. Place a soft towel on the rear fender and remove the fuel cap to avoid any scratches or damage to the tank. This will allow you to access the fuel pump assembly for removal.

For pre-2008 models, there are two additional fasteners located under the fuel filler door. Remove these fasteners and carefully lift the canopy/fuel pump assembly. Cut the hose clamp securing the corrugated tube in place, being careful not to let the cut clamp fall into the tank. The fuel pump assembly sits in an "L" position and must be unlocked and unfolded to remove it from the tank. Use a screwdriver or similar tool to depress the black locking tab and allow the pump to swing open.

For 2008 and newer models, Harley-Davidson changed to a more compact fuel pump design, so the removal process is slightly different. Disconnect the fuel pump harness plug and fuel vapor vent line. Using a hammer and punch (or a similar blunt object), gently tap the locking ring tabs in a counter-clockwise direction to free the locking ring. Alternatively, you can use a locking ring removal tool if available. Lift the fuel filter assembly out of the tank and disconnect the quick-connect fuel lines running to the filter housing.

Once the fuel pump assembly is removed, you can proceed to replace the fuel filter and pump, if necessary.

Removing the fuel pump assembly

The following steps are for pre-2008 Harley-Davidson touring models.

Disconnect the fuel pump harness plug and fuel vapour 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 in place. Be careful not to let the cut clamp fall into the tank.

The fuel pump assembly sits in an "L" position in the tank and must be unlocked and unfolded to allow the pump to be lifted out. Using a screwdriver or similar tool, depress the black locking tab to allow the pump to swing open.

Now, the pump can be lifted out of the tank.

For 2008 and newer models, the removal process is different. Disconnect the fuel pump harness plug and fuel vapour vent line. Using a hammer and punch (or similar blunt object), tap the locking ring tabs in a counter-clockwise direction to free the locking ring. A locking ring removal tool can also be used.

Lift the fuel filter assembly out of the tank and disconnect the quick-connect fuel lines running to the filter housing. The pump assembly sits on the bottom of the tank and can now be pulled out.

Frequently asked questions