Mercedes Mullins
Installing a fuel filter on your Harley-Davidson is a straightforward process, but it's important to follow the correct steps to ensure your bike runs smoothly and efficiently. The fuel filter is located inside the fuel tank and is part of the fuel pump assembly. To replace it, you'll need to remove the tank dash and various components on top of the tank. Using a fuel pump assembly removal tool, loosen and lift out the old filter, being careful not to damage any components. Install the new filter, ensuring proper alignment, and test the fuel system for correct fuel flow and pressure. Regularly replacing your fuel filter will help maintain your Harley-Davidson's performance and fuel efficiency.
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What You'll Learn
Locating the fuel filter
For Harley-Davidson Touring models from 2000 to 2015, the fuel tank removal process is straightforward and necessary for most accessory installations. First, remove the left saddlebag and side cover. Then, disconnect and reconnect some wires during reassembly.
For older models, such as the 2007 Road King, you may need to replace the original fuel hose from the tank's quick-release to the throttle body. The original hard plastic fitting that goes into the quick release can cause the check valve to shut off the fuel flow, leading to issues.
It is recommended to refer to your specific Harley-Davidson model's service manual for detailed instructions on locating and replacing the fuel filter. The service manual will provide information on the recommended replacement intervals, which can vary from 25,000 to 100,000 miles, depending on the model.
Additionally, some models may have the fuel filter located in a different area, so consulting the manual or seeking assistance from a Harley-Davidson dealer or an independent shop is advised if you are unsure.
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Removing the old filter
To remove the old fuel filter from your Harley-Davidson, you'll need to first locate it inside the fuel tank. To access the fuel filter, you'll need to remove the tank dash and various components on top of the tank. The filter is part of the fuel pump assembly and is secured by a ring.
Using a recommended tool such as the Lisle fuel pump assembly removal tool, loosen the ring that secures the old fuel filter in place. Carefully lift the ring and the old filter out of the pump assembly, being mindful not to damage any components. Make sure to dispose of the old fuel filter and o-ring properly. During this step, you can also check for any signs of clogging or debris that could affect the fuel system.
It is important to note that fuel pressure should be relieved before any work is done on the fuel system, as the fuel pump can maintain pressure for days even when the bike is turned off. Purging the system eliminates the possibility of accidental fuel spray.
Additionally, when removing the old filter, pay attention to the proper alignment of tabs and pins. This will be important when installing the new fuel filter to ensure correct operation and peak performance.
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Installing the new filter
To install a new fuel filter on your Harley-Davidson, you'll first need to locate the old filter inside the fuel tank and remove it carefully, along with the o-ring. It is recommended to use the correct tool, such as the Lisle fuel pump assembly removal tool, for ease and to prevent damage.
When installing the new filter, ensure the proper alignment of tabs and pins before securing the filter in place on the pump assembly. This step is crucial for the correct operation of the fuel system.
After installing the new filter, you should test the fuel system for correct fuel flow, pressure, and functionality. Use a fuel pressure gauge to measure the pressure and ensure it is within the manufacturer's specified range. This confirms that the fuel filter replacement was successful and that the system is functioning correctly.
Additionally, during filter maintenance, you can troubleshoot by checking for any signs of clogging or debris that could affect the fuel system. Regular replacement of the fuel filter is essential to ensure your Harley-Davidson's engine receives the necessary fuel supply for optimal performance.
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Testing the fuel system
Locate the Fuel Pressure Gauge Port:
The fuel pressure gauge port is typically located on the right side of your Harley Davidson, between the cylinders, near the bottom of the throttle body. It may resemble a tire valve stem with a cap on it.
Acquire a Fuel Pressure Gauge:
You can purchase or rent a fuel pressure gauge from auto parts stores such as AutoZone or Advance Auto Parts. This tool is essential for measuring the fuel pressure in your system.
Screw on the Fuel Pressure Gauge:
Attach the fuel pressure gauge to the port securely. Ensure it is screwed on tightly to get an accurate reading.
Turn on the Ignition:
With the fuel pressure gauge in place, turn on the ignition switch. Listen for the fuel pump to run, and observe if the system builds up pressure.
Start the Engine:
Once the engine is started, pay attention to the fuel pressure gauge. The pressure should be maintained within the manufacturer's specified range, typically around 58 to 60 psi for Harley Davidson motorcycles.
Inspect for Leaks:
While the engine is running, carefully open the fuel tank and use a flashlight to inspect for any signs of leaks, such as a spray or mist in the tank. This could indicate a cracked fuel flange or other issues.
Check Injectors:
Turn off the engine and remove the air box cover and air filter. Inspect the injectors for any signs of clogging or debris. Ensure that the butterflies are in the correct position and properly timed.
Verify Fuel Flow and Pressure:
After installing the new fuel filter, confirm that the fuel system is functioning correctly by verifying proper fuel flow and pressure. Use the fuel pressure gauge to ensure that the pressure is within the specified range.
By following these steps and paying close attention to the fuel system's performance, you can ensure that your newly installed fuel filter is functioning optimally and that your Harley Davidson's fuel system is in good condition.
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Maintenance tips
First, locate the fuel filter by removing the tank dash and various components on top of the tank. The filter is part of the fuel pump assembly and is usually secured by a ring. It is important to use the correct tool to prevent damage and make the process easier. The recommended tool is the Lisle fuel pump assembly removal tool, which can be purchased online.
Once you have located the filter, carefully remove it from the assembly, ensuring you do not damage any components. Dispose of the old filter and o-ring properly. Check for any signs of clogging or debris that could affect the fuel system.
Install the new fuel filter, ensuring proper alignment of tabs and pins. Secure the filter in place and test the fuel system for correct fuel flow, pressure, and functionality. Use a fuel pressure gauge to measure the pressure and ensure it is within the manufacturer's specified range.
Regular replacement of the fuel filter is important to ensure your bike's engine is performing at its best. Harley-Davidson recommends a maintenance interval of 25,000 miles, but some owners opt to replace it sooner if they notice any issues. A dirty fuel filter can cause a loss of performance and poor running, so it is worth checking and replacing if necessary.
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Frequently asked questions
Harley Davidson recommends replacing the fuel filter every 25,000 miles. However, some owners have reported replacing their fuel filters at 10,000 miles due to clogging or other issues. On the other hand, some owners have travelled up to 100,000 miles without replacing the filter.
It is recommended to use the Lisle fuel pump assembly removal tool, which is available on Amazon for around $30. You may also need a special wrench if you have a 2009 model or newer.
The fuel filter is located inside the fuel tank. To access it, you will need to remove the tank dash and various components on top of the tank.
The fuel filter is secured by a ring that must be removed for replacement. Use the Lisle fuel pump assembly removal tool to loosen the ring, then lift it and the old filter out of the pump assembly carefully. Make sure to dispose of all parts properly.
Ensure proper alignment of tabs and pins before securing the new filter in place on the pump assembly. Test the fuel system for correct fuel flow and pressure using a fuel pressure gauge to ensure it is within the manufacturer's specified range.
