Katerina Swanson
The Harley-Davidson Sportster is a powerful bike with sleek lines, but its small fuel tank means frequent pit stops. If you want to empty the tank of your 2009 Harley 1200 Sportster, there are a few methods you can try. Some people suggest running the tank empty, while others recommend disconnecting the fuel hose from the tank bung and the throttle body, or using a fuel tool. You can also try removing the seat and fuel line, and then the bolts securing the tank.
Characteristics and Values Table for Emptying the Fuel Tank on a 2009 Harley 1200 Sportster
| Characteristics | Values |
|---|---|
| Fuel Tank Removal Process | Disconnect the fuel line, remove the overflow tube, disconnect the fuel pump connector, and remove the bolts securing the tank. |
| Fuel Drainage Methods | Using a hose and fuel can, siphoning, or removing and inverting the tank. |
| Fuel Storage | Use a stabilizer to prevent corrosion during winter storage. |
| Fuel Pump Removal | Unscrew the five Torx screws underneath the tank. |
| Fuel Line Disconnection | Pull the ring and hose, then follow the wire harness to the connector below the seat. |
| Fuel Shut-Off | No manual shut-off on EFI Sportsters, but can be drained using the Fuel Tool or by running the bike until it runs out of gas. |
| Fuel Tank Upgrade | Possible to upgrade to a larger fuel tank without compromising the bike's aesthetics or handlebar/mirror clearance. |
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What You'll Learn
Disconnect the fuel line
Disconnecting the fuel line on your 2009 Harley 1200 Sportster is a straightforward process, but it requires careful attention to ensure no fuel leaks occur. Here is a detailed guide on how to do it:
First, locate the fuel line. It is connected to the fuel tank and can be identified by its resemblance to an air hose fitting. Simply pull the ring and gently pull the hose to disconnect it. There may be a small amount of fuel that escapes from the fitting, so have a cloth or container ready to catch any spills.
If you want to completely empty the fuel tank, there is a method to do so safely. Start by pulling the fuse for the fuel pump, then attempt to start the bike. Only a small amount of fuel will leak when you disconnect it. Locate the 15-amp fuse in the fuse panel next to the battery; it's on the top right or in the middle slot if there are two fuses. Pull the fuse, and after attempting to start the bike, hold the starter for a few seconds to clear any remaining fuel from the line.
Next, disconnect the vent hose. This is located on the left side of the bike, near the seat, and up and left from the battery at the bottom of the tank. Ensure you do not run the pump for too long without fuel to avoid any damage to the system.
Now, to drain the fuel, you will need to set up a siphoning system. Locate the fuel pump and remove it. Find a piece of hose long enough to reach from the fuel line to a fuel can. Connect one end of the hose snugly to the fuel line and place the other end into the fuel can. Use a jumper wire from the fuse terminal to the positive battery terminal to turn on the pump. Leave the bike on its side stand and run the pump until the tank is completely empty.
Finally, when you are finished, remember to reconnect everything as it was when you started. Ensure that all connections are secure and tight to avoid any fuel leaks when riding your Harley.
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Remove the overflow tube
To remove the overflow tube from your 2009 Harley 1200 Sportster, you'll first need to disconnect the fuel line and the fuel pump connector, which is located down on the frame near the fuses.
Next, remove the two bolts securing the tank. You can then attempt to lift or slide the tank off. Be careful, as there may be electrical connections still attached, and you don't want to force anything.
If you don't want to leak fuel everywhere, pull the fuse for the pump and then start the bike. Only a small amount of fuel will leak when you disconnect it. If you're looking at the fuse panel next to the battery, it's the 15-amp fuse on the top right. Pull that fuse, start the bike, and hold the starter for a few seconds to clear any fuel from the line.
It's also important to disconnect and reconnect the vent hose. If you're sitting on the bike, it's on the left, up and to the left of the battery at the bottom of the tank.
Finally, when you reinstall the fuel line, ensure it's securely connected, or it will spray fuel when you turn on the pump.
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Disconnect the fuel pump connector
Disconnecting the fuel pump connector on a 2009 Harley 1200 Sportster is a relatively straightforward process. Here is a detailed, step-by-step guide on how to do it:
First, remove the seat of the motorcycle to access the fuel tank and its components. This will expose the fuel line and other relevant parts. It is important to note that there is no fuel shut-off valve on EFI Sportsters, so you will be dealing with an air-type fitting.
Next, locate the fuel pump connector. It is usually found near the fuses and the battery. Follow the wire harness down from the fuel tank to find the connector. You may need to refer to a diagram or a manual to identify the exact location of the connector and the fuses.
Once you have located the connector, you will need to remove the fuse for the fuel pump. This will depressurize the fuel line and prevent fuel leakage. Be sure to do this with the engine running. The fuse box is typically located under the seat or near the battery. Remove the appropriate fuse, which is usually a 15-amp or 20-amp fuse.
After removing the fuse, start the bike. The bike will die, but hold the starter for a few seconds to clear any remaining fuel from the line. This step is crucial to ensure that fuel does not spray out when you disconnect the fuel line.
Now, you can proceed to disconnect the fuel line from the fuel pump. Pull on the ring and gently pull off the hose. There may be a small amount of fuel that comes out, but it should not pour out. Be cautious and have a container ready to catch any fuel that may spill.
Finally, with the fuel line disconnected, you can now focus on the fuel pump connector itself. It is usually secured with bolts or screws. Using the appropriate tools, carefully loosen and remove the bolts holding the connector in place. Be mindful of any electrical connections and wires, and ensure that you do not force anything if it feels resistant.
By following these steps, you will have successfully disconnected the fuel pump connector on your 2009 Harley 1200 Sportster. Remember to work carefully and refer to a mechanic or a professional if you encounter any issues or complications.
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Remove bolts securing the tank
To remove the bolts securing the tank of a 2009 Harley 1200 Sportster, you must first remove the seat. The fuel line comes off the tank like an air hose fitting. Pull the ring and pull off the hose. There will be a small amount of fuel from the fitting, but it won't pour out.
Follow the wire harness down to the connector below the seat in front of the battery cover. Remove the two bolts securing the tank and remove it. When you reinstall the fuel line, ensure it is correctly connected, or it will spray fuel when you turn on the pump.
If you don't want to leak fuel everywhere, pull the fuse for the pump, then start the bike. Only a little fuel will leak when you disconnect it. If you're looking at the fuse panel next to the battery, it's the 15-amp fuse on the very top right. Pull that fuse, start the bike, and hold the starter for a few seconds to clear any fuel from the line.
Make sure you disconnect and reconnect the vent hose. If you're sitting on the bike, it's on the left, nearer the seat and up and left from the battery at the bottom of the tank.
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Remove the seat
To remove the seat of a 2009 Harley 1200 Sportster, follow these steps:
First, locate the screw at the back of the seat and use the appropriate tool to unscrew it. This will loosen the seat, but it will not come off completely yet. There is no need to worry about a fuel shut-off, as the 2009 Harley 1200 Sportster does not have one.
Next, you will need to push the seat forward while simultaneously lifting the rear of the seat straight up. It may take a bit of force and wiggling to get the seat to come off, but it will eventually pop off. Be careful not to scratch the bike or the seat during this process.
If your seat has a locating pin, which is common on Sportsters, you may need to remove it to fully remove the seat. The locating pin is usually at the rear of the seat and plugs into the rear fender. Once the pin is removed, you can completely separate the seat from the bike.
Some older Harley models have a quarter-inch-20 nut welded into the fender, while newer models have a simple hole with a locating notch. If your bike has the welded nut, you will need to remove it to take off the seat.
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Frequently asked questions
There are a few ways to empty the fuel tank on your Harley. One way is to disconnect the fuel line, remove the overflow tube, disconnect the fuel pump connector, and remove the bolts on the tank. Another way is to use a fuel tool to drain the tank. You can also siphon the gas out of the tank by starting the bike and letting it run out of gas.
No, you don't need to empty the tank to remove it unless you want to remove the fuel pump.
To disconnect the fuel line, pull the ring and pull off the hose. There will only be a small amount of fuel that comes out.
