Mercedes Mullins
Removing a non-fuel-injected gas tank from a Harley-Davidson motorcycle can be intimidating, but the process is quite simple. Before removing the tank, it is important to drain the fuel. This can be done by riding the bike until the tank is almost empty, or by siphoning the fuel into a suitable container. Once the tank is drained, the next steps involve removing the dash, bolts, and fuel lines, before carefully lifting the tank off the bike.
Explore related products
What You'll Learn
Remove dash and bolts
To remove the dash and bolts of a non-fuel-injected gas tank on a Harley, you will need to first expose the fuel lines. Start by pulling up the rubber skirt under your gas cap. Next, locate the fuel out line and remove it by pinching the blue tabs. Now, attach a suitable hose to the fuel out line and place the other end in a proper container.
The next step is to locate and remove the fuse for the fuel pump. Save it in a safe place so you can reinstall it later. Then, find an old or unused fuse and, using pliers, break it and remove one of the blades. Insert the single blade into the side of the fuse that the wire goes to the fuel pump.
With the bike turned off, use a wire to jump from the positive terminal on the battery to the blade. This will activate the fuel pump, allowing you to empty the tank. Once the tank is empty, disconnect the wire.
Now, you can proceed to remove the dash and bolts. Remove the bolts holding the tank at the front and rear. Be sure to have a catch pan or bucket underneath to catch any remaining fuel. Once the bolts are removed, carefully lift the tank up and off the bike. Place the tank to the side and continue with any further modifications or repairs that require access to the area under the fuel tank.
Capless Fuel Tanks: How Do They Work?
You may want to see also
Explore related products
Disconnect fuel lines
Disconnecting the fuel lines is a crucial step in removing a Harley non-fuel-injected gas tank. Here is a detailed guide on how to do it:
First, pull up the rubber skirt located underneath your gas cap. This will expose the fuel lines. Locate the fuel outlet line, which is where the fuel exits the tank. It is important to note that the fuel outlet line is different from the fuel injection line, which supplies fuel to the engine. Once you have located the fuel outlet line, pinch the blue tabs to remove it. This will allow you to disconnect the fuel line from the tank.
Next, you will need to find a suitable hose that can be attached to the fuel outlet line. One end of this hose should be connected to the fuel outlet line, while the other end should be placed in a proper container. This container will catch the fuel that drains out of the tank. Make sure that the container is large enough to hold the amount of fuel in the tank and that it is placed securely underneath the outlet to avoid any spills.
In some Harley models, there may be a crossover line or hose that needs to be removed or clamped before you can access the fuel lines. This is a common feature in Harley motorcycles, and removing it safely can make the process of detaching the fuel tank easier.
Additionally, it is important to locate and remove the fuse for the fuel pump. The fuel pump is responsible for drawing fuel from the tank and supplying it to the engine. By removing the fuse, you can prevent the fuel pump from activating during the tank removal process, reducing the risk of fuel leakage or spillage. Make sure to keep the fuse safely aside so that it can be reinstalled once the new tank is in place.
Finally, it is recommended to drain as much fuel as possible from the tank before attempting to remove it completely. This can be done by using a siphon or a similar tool to extract the fuel. Working with a near-empty tank reduces the risk of fuel spills, making the process safer and less messy.
Where to Dispose of Old Fuel Oil Tanks?
You may want to see also
Explore related products
Drain the tank
To drain the tank of your Harley, you must first expose the fuel lines. Start by pulling up the rubber skirt under your gas cap. Then, locate your fuel out line and pinch the blue tabs to remove it. Attach a suitable hose to the fuel out line and place the other end of the hose into a container to catch the fuel.
Next, locate the fuse for the fuel pump and remove it. Keep it safe so that you can reinstall it later. Now, find an old or unneeded fuse and, using pliers, break it and remove one of the blades. Insert the single blade into the side of the fuse that the wire goes to the fuel pump. With the bike turned off, use a wire to jump from the positive terminal on the battery to the blade. The fuel pump will then empty the tank.
Alternatively, you can simply ride your bike until the fuel in the tank is low, then refill it with fresh fuel. If the pump is inoperable, you can siphon the fuel out.
Trailblazer Fuel Tank: Gallons Capacity and Efficiency
You may want to see also
Explore related products
Disconnect wiring
Disconnecting the wiring on your Harley is a crucial step in removing the gas tank, and it's important to do it safely and effectively. Here's a detailed guide on how to disconnect the wiring when removing a non-fuel-injected gas tank from your Harley:
First, locate the fuel lines. You can do this by pulling up the rubber skirt under your gas cap. Once you've exposed the fuel lines, find the fuel outflow line. It's important to pinch the blue tabs to remove it, and then attach a suitable hose to drain the fuel into an appropriate container.
Next, you'll need to locate and remove the fuse for the fuel pump. Make sure to keep it safe so you can reinstall it later. This step ensures that you don't accidentally activate the fuel pump while working on the tank.
Now, find an old or unused fuse and use pliers to break it and remove one of its blades. Insert the remaining single blade into the side of the fuse that connects to the fuel pump wire. With the bike turned off, use a wire to jump from the positive terminal on the battery to the exposed blade. This will ground the circuit and allow you to safely drain the fuel tank.
At this point, you can activate the fuel pump to empty the tank. Remember to disconnect the wiring once the tank is empty.
Additionally, you'll need to disconnect the fuel injection wiring harness. This harness provides power and control to the fuel injection system. It's important to carefully detach it to avoid any damage.
Finally, locate and disconnect the overflow and main flow lines. These lines are responsible for the fuel flow into and out of the tank. By disconnecting them, you ensure that the tank can be safely removed without any fuel leaks.
Remember to exercise extreme caution when working with fuel and electricity. Always wear the appropriate protective gear and ensure proper ventilation to mitigate the risk of fire and fumes.
By following these steps, you can effectively disconnect the wiring when removing a non-fuel-injected gas tank from your Harley, making it a safe and efficient process.
Installing a Fuel Tank Float in an Isuzu Rodeo
You may want to see also
Explore related products
Lift tank off the bike
Lifting the tank off the bike is the final step in removing a Harley non-fuel-injected gas tank. Before lifting the tank off, you must remove the dash, the bolts holding the tank at the front and rear, the crossover line, and disconnect the two lines. You should also remove the fuel. This can be done by using a siphon to remove as much gas as possible, then draining any remaining fuel into a container.
Once the tank mounting bolts are removed, the fuel injection wiring harness disconnected, the overflow and main flow lines are disconnected, you are ready to lift the tank off the bike. It is important to carefully set the tank to the side.
If you are clamping the two hoses with two hose clamp pliers, this may reduce the gas spill potential. You should also put a catch pan underneath when removing the tank.
When reinstalling the tank, you do not need to worry about the order of connections, but you must ensure everything is correctly connected and secured tight.
Tractor Fuel Tank Capacity: How Much Can It Hold?
You may want to see also
Frequently asked questions
To remove the gas tank from your Harley, you must first remove the dash and bolts holding the tank at the front and rear. Then, disconnect the fuel lines and the crossover line. Finally, lift the tank up and off the bike.
To disconnect the fuel lines, first pull up the rubber skirt under your gas cap to expose the fuel lines. Next, locate your fuel out line and pinch the blue tabs to remove. Attach a suitable hose and insert the other end into a container to catch the fuel.
To remove the crossover line, first clamp the hose on both sides of the centre that is in front of the frame. Then, use diagonal cutters to break the stock hose clamp and remove the two halves of the hose.
