Ameer Randolph
The Harley-Davidson Sportster is a powerful bike with sleek lines and an awesome power plant. However, it has a small fuel tank, which means riders have to make frequent pit stops. Owners of the 1987 model have also complained about the short miles between fill-ups. If you're looking to install a fuel line on your 1987 Harley Sportster, you'll need to consider the size of the fuel line, whether to use a clamp, and the type of fuel line you want.
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What You'll Learn
Removing the gas tank
The process is quite straightforward and is required for most touring model accessory installations. You will need to access parts under the fuel tank for many improvements, modifications, and repairs. Don't be intimidated by the process, as it is easier than it may seem.
It is important to be careful when handling the gas tank and to ensure that all connections are secure and tight when installing any new parts. Once you have finished, take your bike for a test ride to ensure everything is functioning correctly.
The gas tank on the 1987 Harley Sportster is relatively small, which can be a common complaint among owners who have to make frequent fill-ups. There are options to upgrade to a larger fuel tank without compromising the sleek lines of the Sportster or causing clearance issues with handlebars or mirrors.
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Choosing the right fuel line
When choosing the right fuel line for your 1987 Harley Sportster, there are a few things to consider. Firstly, the size of the fuel line is important. Some sources suggest that the fuel line for this specific model is 1/4 inch, while others mention options for a 5/16 inch fuel line. It's crucial to get the right size to ensure a proper fit and avoid any leaks.
Another aspect to consider is the style of the fuel line. Braided fuel lines, for example, can add a stylish touch to your bike. They can be matched with braided clutch and brake lines for a cohesive and aesthetically pleasing look. If you want to showcase the fuel flow, you can even opt for clear fuel lines.
The functionality and performance of the fuel line are also key factors. Fuel lines can become clogged over time due to fuel degradation and debris. Therefore, it's important to consider fuel filters and petcocks, as they play a crucial role in keeping your engine free from damaging debris. Regular cleaning or replacement of these components is necessary to maintain optimal performance.
Additionally, you may want to explore fuel lines with EFI (electronic fuel injection) for added convenience and performance. It's worth noting that fuel lines are relatively inexpensive parts, but they play a vital role in preventing expensive damage to your Harley's engine.
Lastly, when choosing a fuel line, consider the ease of installation. Some fuel lines may require additional adjustments or modifications, so opting for a fuel line that is compatible with your bike's specific connectors and fittings can make the installation process much smoother.
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Replacing the fuel petcock
Firstly, you will need to source a replacement petcock. You can find these for sale online, and it is worth checking Harley forums for advice on specific models and compatibility. You will also need to decide on the style of petcock you want. Braided fuel lines, for example, can add a stylish touch to an otherwise simple component.
Once you have the replacement part, it is recommended to watch a demonstration video of the process before attempting it yourself. This will give you a better idea of the steps involved and ensure you feel confident in tackling the task. The basic process involves removing the old petcock and installing the new one, ensuring a secure connection to prevent leaks.
Finally, it is important to note that a petcock is a simple ball valve, and its function is indicated by the position of the lever. If the lever is in line with the feed hose, the valve is on; if it is perpendicular to the feed line, it is off. With Pingel petcocks, the lever moves side to side but still functions in the same way.
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Upgrading to a larger fuel tank
Firstly, it's important to understand the fuel system of your Sportster. The fuel line on a 1987 model is likely 1/4 inch, and you may need to replace the fuel petcock, as the original part may be obsolete. There are a few options available, such as the Pingel or Golan, which have 5/16 fuel outlets. You can either use a 5/16 inch fuel line with a clamp or a 1/4 inch fuel line with an appropriate adapter.
Now, let's discuss the process of upgrading to a larger fuel tank. The first step is to determine the compatibility of the new tank with your bike's year and model. Most Evo Sportster models (1985-2003) will bolt right up to the frames of other Evo models, so if you have a 1987 Sportster, you're in luck! If you're considering a significant increase in fuel capacity, keep in mind that you may need to also upgrade the fuel valve (petcock) to ensure it's on the same side as the tank to avoid clearance issues.
When choosing a new fuel tank, you have a few options. The most common Sportster tanks are the 2.2 and 3.3-gallon versions. If aesthetics are important to you, the 3.3-gallon tank is a great option as it bolts right up to the frame of your 1987 Sportster. For even more fuel capacity, you can consider aftermarket options like the Fat Bob-style tanks that hold up to 5 gallons of fuel.
The next step is the installation process. Before you begin, make sure you have all the necessary tools and safety equipment, such as gloves and eye protection. Drain the existing fuel tank and remove it from the bike, taking note of the fuel line connection and any other attached components. Carefully install the new fuel tank, ensuring that all connections are secure and properly sealed to prevent leaks. Pay close attention to the fuel line, making sure it is routed correctly and securely clamped.
Finally, once the new tank is installed, it's important to check for leaks and ensure that the fuel system is functioning properly. Start by filling the new tank with fresh fuel, checking for any signs of leakage. Then, test ride your bike to ensure that the fuel system is working as expected.
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Installing a fuel management system
Step 1: Understand the Fuel System Components
Before beginning the installation, it's crucial to have a basic understanding of the fuel system components and their functions. The fuel management system consists of the fuel line, fuel filters, petcocks, and, in some cases, a fuel tank upgrade. The fuel line delivers fuel to the engine, while the fuel filters and petcocks work together to prevent debris and contaminants from entering the engine, ensuring smooth fuel flow.
Step 2: Gather the Necessary Parts and Tools
Ensure you have all the necessary parts and tools for the installation. This includes the fuel management system kit, which may include a fuel line, filters, and petcocks. You may also consider upgrading to a braided fuel line for added style and durability. Additionally, basic tools like wrenches, screwdrivers, and a manual or an instructional video specific to your model may be helpful.
Step 3: Remove the Old Fuel Line and Components
Carefully remove the old fuel line and any related components, such as the fuel tank, fuel injection wiring harness, and fuel lines. This process can vary depending on your Sportster's specific model and year, so refer to your manual or a trusted online resource for detailed instructions. For example, you may need to disconnect the wiring harness and overflow and main flow lines before lifting the tank off the bike.
Step 4: Install the New Fuel Line and Components
Install the new fuel line and any additional components included in your fuel management system. Ensure that all connections are secure and tight to prevent leaks. Follow the instructions provided with your fuel management system kit carefully, as the steps may vary depending on the specific kit and your Sportster's configuration.
Step 5: Test and Adjust as Needed
Once the new fuel line and components are installed, test the system by taking your Sportster for a test ride. Pay attention to how the bike performs and make adjustments as needed. Ensure that the fuel management system functions optimally and that there are no leaks or issues with fuel delivery.
Step 6: Maintain and Care for Your New Fuel Management System
Regular maintenance and care will help ensure the longevity and performance of your new fuel management system. Keep the fuel lines, filters, and petcocks in good working order by periodically inspecting and replacing them as needed. Consider using fuel additives to help keep the system clean and functioning correctly.
Remember, seamless fuel delivery is crucial to the performance of your Harley engine. By installing a fuel management system, you can improve fuel flow, protect your engine, and enhance the overall riding experience. Always refer to your Sportster's manual or seek advice from experienced mechanics or Harley-Davidson forums for specific guidance on maintaining and upgrading your bike.
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