Sylvie Willis
Removing a fuel tank from a Fatboy motorcycle involves several steps. First, relieve the fuel pressure and drain the tank. Disconnect the wiring from the console to the tank, the vent hose, and the fuel line. Remove the dash, leather strap, and any other obstructions. Disconnect the fuel gauge wires and remove the fuel cap. With the tank still tilted, put the crossover hose back on. Finally, slowly lift up the tank, being careful not to hit the bars, and completely remove it from the bike.
How to Remove a Fatboy Fuel Tank
| Characteristics | Values |
|---|---|
| Step 1 | Remove the seat |
| Step 2 | Turn the fuel switch off (or remove the fuel line) |
| Step 3 | Disconnect the wiring from the console to the tank |
| Step 4 | Disconnect the vent line, if present |
| Step 5 | Disconnect the fuel line on the tank |
| Step 6 | Disconnect the fuel gauge |
| Step 7 | Remove the dash, leather strap (if applicable) and anything else in the way of the pump |
| Step 8 | Remove the front and rear mounting bolts for the tank |
| Step 9 | Remove the vacuum line attached to the top of the tank, if present |
| Step 10 | Remove the fuel cap |
| Step 11 | Remove the pump plate |
| Step 12 | Lift the plate/pump out of the tank |
| Step 13 | Remove the hose from the back of the pump |
| Step 14 | Go to the right side of the bike. Loosen the right tank fitting clamp and remove the right side of the crossover line |
| Step 15 | Slowly lift up the tank |
| Step 16 | Undo the gauge connector on the left lower side of the tank |
| Step 17 | Completely remove the tank from the bike |
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What You'll Learn
Remove the dash, leather strap, and anything else blocking the pump
To remove the dash, leather strap, and anything else blocking the pump, you will need to first remove the seat. Then, turn off the fuel switch or remove the fuel line if your bike has a vacuum switch.
Now, you can start removing the dash and the leather strap. When removing the dash, carefully swing it over the bars and leave it hanging there. You can lay a towel on the bars to prevent scratches. You may also want to tape the dash to ensure it doesn't fall off.
Under the dash, you will find wiring harnesses: one to the speedometer, one main harness, one to the ignition switch, and one to the reset button for the odometer. Remove these wires and tie them with a zip tie to keep them in place. Next, remove the vent hose located in front of the tank at the top.
If you have a vacuum line attached to the top of the tank, remove it. You will also need to remove the fuel cap and the pump plate, which is attached with screws. Be mindful of the little plastic spacers when removing the screws.
By following these steps, you will be able to clear the area around the pump and gain access to the fuel tank for removal.
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Remove the fuel cap and fuel line
Removing the fuel cap and fuel line is a crucial step in detaching a Fatboy fuel tank. The process can vary slightly depending on the model year of your Fatboy, but here is a comprehensive guide to help you through the process.
First, ensure that you have relieved the fuel pressure and drained as much fuel as possible from the tank. This step is essential for safety and to avoid spills. You can drain the tank by siphoning the fuel or removing the crossover tube at the front of the tank. If you choose to keep the fuel in the tank, be sure to block off the crossover lines.
Next, locate the fuel cap and fuel line. The fuel cap is typically found on top of the tank, while the fuel line is connected to the bottom of the tank. If your Fatboy has a vacuum line attached to the top of the tank, be sure to remove it as well.
Now, carefully remove the fuel cap. Depending on the model, you may need to use a special tool or a paper clip to disassemble the connector and remove the fuel cap. Be cautious when handling the fuel cap, as it may have residual fuel.
Then, proceed to undo and detach the fuel line. On Softail models, there is usually a quick-release connector located on the left rear bottom of the tank. Undo this connector and carefully remove the fuel line. If your Fatboy has a fuel pump, you may need to push down on it to release it from the top cap. Removing the fuel line may require some force, but be cautious not to damage any surrounding components.
Finally, once the fuel cap and fuel line are removed, make sure to securely cap or plug any open fuel lines to prevent leaks and ensure safety. It is recommended to have rags or absorbent materials nearby to wipe up any residual fuel.
Remember to refer to your specific model's manual for detailed instructions, as some variations may exist between different model years of the Fatboy. Always prioritize safety and have a helper assist you if possible when removing the fuel tank.
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Disconnect the fuel gauge
Disconnecting the fuel gauge is a crucial step in removing the fuel tank of a Fatboy motorcycle. Here is a detailed guide on how to do it:
First, it is important to relieve fuel pressure and drain the tank as much as possible. This step ensures that you are working with minimal fuel, reducing the risk of spills and accidents. You can do this by removing the fuel hose to the petcock, as once the bike is started, it will suck up the remaining gas.
Next, locate the fuel gauge wire. This wire is usually found under the tank on the left side, towards the seat area. Be cautious when fishing out this wire to avoid any damage. It is recommended to have an extra pair of hands to help with this step.
Once you have located the wire, carefully disconnect it. There should be a connector that holds the wire in place. Using a tool, such as a paper clip or a specialised tool from Harley, disassemble the connector and then pull out the entire assembly, including the wires.
After disconnecting the wire, you may need to remove the fuel gauge itself. This process involves checking the resistance of the sending unit, which is the component that works in conjunction with the fuel gauge to measure fuel levels. Remove the screws holding the sending unit in place and lift it out, being cautious not to spill any remaining fuel.
Finally, always remember to work with safety in mind. When dealing with gasoline and explosive fumes, take the necessary precautions, such as working in a well-ventilated area and avoiding any open flames or sparks.
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Remove the front and rear mounting bolts
To remove the front and rear mounting bolts, start by removing the dash, leather strap, and anything else blocking access to the pump. This includes the wiring harness, which you should carefully lace up and secure with zip ties. Then, remove the vent hose located in front of the tank at the top. Next, you can remove the fuel cap and the pump plate, being mindful of the plastic spacers. Once the pump plate is removed, you can start lifting the plate/pump out of the tank.
Now, you can focus on the mounting bolts. First, remove the front tank bolt. Then, remove the Star bolt holding the tank in place on the center spline towards the seat area. Be cautious when fishing out the wire from under the tank and ensure you disconnect it. At this point, you can pull back slightly on the tank and then lift it up. You will notice a rubber gasket on the front frame with wires running through it.
It is important to have a clear understanding of the procedure and take necessary precautions to avoid any damage or scratches to your Fatboy fuel tank and its components.
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Lift the tank slowly
Lifting the tank slowly is the final step in the process of removing a Fatboy fuel tank. Before you get to this stage, you will have already removed the dash, leather strap, and anything else blocking the pump. You will also have removed the front and rear mounting bolts, the vacuum line, and the fuel cap.
Now, slowly lift the tank. It is best to have someone help you with this step. As you lift, undo the gauge connector on the left lower side of the tank. Be careful not to hit the bars when removing the tank. If your bike is sitting on the ground and not on a lift, you may want to temporarily move the bars to the straight position.
Once the tank is lifted, you can completely remove it from the bike. Be sure to avoid snagging any stray lines as you do so. You may also need to remove the fuel gauge wires. To do this, disassemble the small Deutsch connector at the end using a special tool from Harley or a paper clip. Then, pull the whole assembly out, and the wires will follow through the small guide tube protruding from the bottom of the tank.
If you are leaving the fuel pump in, you can mask off the fuel ring (or bung) with tape. To remove the wires, open the little door and pull them out with needle-nose pliers. You can then use a sewing needle or something similar to push in and release the wires.
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Frequently asked questions
Using a VOM (volt/ohm meter), unplug the connector beneath the tank and check for voltage with the ignition switch on. Once you've finished this test, turn the switch back to the off position. Then, carefully work the gauge up and out of the rubber sleeve.
Remove the seat, then turn the fuel switch off. Unbolt the base and slide the tank off.
It is important to relieve the fuel pressure and drain the tank before removing the fuel tank. You should also be very careful when removing the sending unit, as fuel will spill out if the bike is on its side stand.
