Sylvie Willis
Removing the fuel tank from a Harley-Davidson Sportster motorcycle is a common task for owners who want to make modifications or repairs. The process involves disconnecting the fuel line, removing the overflow tube, disconnecting the fuel pump connector, and unscrewing bolts. It is important to note that there is no fuel shut-off on EFI Sportsters, so there is no need to drain the tank unless internal access is required. Removing the fuel tank is generally considered a simple process, but it requires careful handling of fuel and attention to safety.
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What You'll Learn
Disconnect the fuel line
Disconnecting the fuel line is a crucial step in removing the fuel tank from your Harley-Davidson Sportster. Here is a detailed guide on how to safely and effectively disconnect the fuel line:
First, locate the fuel line and the quick-release mechanism. The fuel line is connected to the fuel tank and can be identified by its resemblance to an air hose fitting. It is important to note that there is no fuel shut-off valve on EFI Sportsters, so you will be working with an open system.
Next, before you disconnect the fuel line, it is recommended to reduce the amount of fuel in the tank to minimise spillage. Running the tank empty is not necessary, but it can make the process neater and safer. Alternatively, if you want to avoid spilling fuel, you can pull the fuse for the pump and then start the bike. This will cause the bike to die, but holding the starter for a few seconds will clear any remaining fuel from the line.
Once you have addressed the fuel level, you can proceed to disconnect the fuel line. Simply pull the ring on the fuel line connection and gently pull the hose off. There may be a small amount of fuel that escapes from the fitting, but it should not pour out. Be cautious and have a cloth or container ready to catch any spilled fuel.
After disconnecting the fuel line, you will need to address the wire harness. Follow the wire harness down to the connector, which is located below the seat, in front of the battery cover. Disconnect the wire harness to completely detach the fuel system from the rest of the bike's electrical system.
Finally, before removing the fuel tank, make sure to also disconnect the fuel pump connector, which is located down on the frame near the fuses. Now that the fuel line and associated connections have been addressed, you can move on to removing the bolts that secure the fuel tank in place.
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Remove the bolts
To remove the bolts, first disconnect the fuel line and remove the overflow tube. You can then disconnect the fuel pump connector, which is located down on the frame near the fuses. Next, remove the two bolts on the tank. One bolt is at the front of the tank, tucked behind the handlebars, and the other is at the back, exposed when you remove the seat. These bolts are both 1/4" Allen bolts with a 1/2" nut. If there is still a rubberized thread protector on the end of the bolt, remove it, then loosen the bolt, take off the nut, and pull the bolt head straight out.
If you are looking to avoid leaking 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 are looking at the fuse panel next to the battery, the fuse you need to pull is the 15 amp one on the top right. Pull the fuse, start the bike, and hold the starter for a few seconds after to clear any fuel from the line. Make sure you also disconnect and reconnect the vent hose. When you reinstall the fuel line, ensure it is on all the way, or it will spray fuel when you turn on the pump.
If you want to remove the fuel pump, you can do so by taking out the five Torx screws underneath.
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Disconnect the fuel pump
Disconnecting the fuel pump is a crucial step in removing the fuel tank on a Sportster motorcycle. Here is a detailed guide on how to do it:
First, it is important to run the tank empty or almost empty before attempting to remove the fuel pump. This will prevent fuel leakage and reduce the risk of spills. Once the fuel level is low, locate the fuel line and the quick-release mechanism. Disconnect the fuel line by pulling the ring and removing the hose. There will be a small amount of fuel left in the fitting, so be prepared to catch it with a suitable container or rag.
Next, follow the wire harness down to the connector below the seat, in front of the battery cover. Here, you will find the electrical wiring that needs to be unplugged from the fuel pump. Make sure to disconnect the vent hose as well, which is located on the left side of the bike, near the seat.
Now, you can remove the bolts securing the fuel pump assembly. There are typically five Torx screws holding the fuel pump in place. Remove these screws carefully, being mindful of any remaining fuel in the tank. Once the screws are removed, carefully take out the fuel pump assembly. This step may require some patience and finesse, so take your time and note how the assembly comes out to make reinstallation easier.
Finally, inspect the fuel pump plate gasket. Ensure that it is seated properly and in good condition. If the gasket is damaged or worn out, it should be replaced before reinstalling the fuel pump.
By following these steps, you can successfully disconnect the fuel pump on a Sportster motorcycle, allowing you to access the fuel tank for removal, maintenance, or upgrades.
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Remove the seat
Removing the seat is the first step in the process of taking off your Harley-Davidson Sportster's fuel tank. The seat screw, which is located on the fender, should be removed with a flathead screwdriver. Then, push the seat forward to release it from the tab in the middle. After the seat has been released, pull it back to free it from the tank's underside tab.
It is important to note that the fuel tank is held in place by only two bolts, one at the front and one at the rear. The rear bolt is hidden under the lip of the seat, so removing the seat is necessary to access this bolt.
Once the seat is off, you will be able to see the rear mounting bolt for the fuel tank. This bolt is located under the lip of the seat and secures the tank to the bike. With the seat removed, you can now proceed to remove the fuel tank by loosening and removing the mounting bolts.
It is worth mentioning that the fuel line disconnects from the tank like an air hose fitting. A small amount of fuel may leak from the fitting when the line is disconnected, but it will not pour out. You can follow the wire harness down to the connector located below the seat and in front of the battery cover.
By following these steps, you will be able to successfully remove the seat and access the necessary components to detach the fuel tank from your Harley-Davidson Sportster.
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Disconnect the vent hose
Disconnecting the vent hose is a crucial step in removing the fuel tank from a Sportster motorcycle. This process can be done safely and effectively by following these steps:
First, locate the vent hose. The vent hose is connected to the fuel tank and is usually found on the left side of the bike, near the seat, and up and to the left of the battery. It is important to identify the vent hose correctly to avoid any confusion with other hoses or wires.
Next, prepare for the disconnection. Place a cloth or a container underneath the vent hose connection to catch any fuel that may spill during the disconnection process. This will help prevent fuel leakage and create a safer work environment.
Now, proceed to disconnect the vent hose. Grasp the vent hose firmly and pull it away from the fuel tank. There may be a ring or a clip securing the hose in place, so ensure that it is properly released before attempting to remove the hose. Be cautious, as a small amount of fuel may drip from the fitting.
After the hose is disconnected, carefully handle it to avoid any spillage. Set the hose aside in a safe place, away from any open flames or heat sources. Ensure that the disconnected end of the hose is positioned upwards to prevent any further fuel leakage.
Finally, it is important to address the fuel line. To prevent fuel leakage from the fuel line, pull the fuse for the fuel pump, and then start the bike. This action will cause the bike to die, and holding the starter for a few seconds will help clear any remaining fuel from the line. This step ensures that the fuel line is empty and reduces the risk of fuel spraying when the fuel pump is turned on.
By carefully following these steps, you can successfully disconnect the vent hose during the process of removing the fuel tank from a Sportster motorcycle.
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Frequently asked questions
Here are the steps to remove the fuel tank from a Harley Davidson Sportster:
- Remove the seat.
- Disconnect the fuel line.
- Remove the overflow tube.
- Disconnect the fuel pump connector.
- Remove the bolts on the tank.
- Pull the ring and pull off the hose.
No, you don't need to drain the tank before removing it unless you want to access the fuel pump or the workings inside the tank.
Just 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.
There are two bolts securing the tank. One is at the front, and the other is hidden under the lip of the seat. They are both 1/4" Allen bolts with a 1/2" nut. Remove the nut and pull the bolt head straight out.
The fuel pump is held in place with 5 Torx screws. It's not difficult to remove, but if you don't want to leak fuel everywhere, pull the fuse for the pump and start the bike. Only a little fuel will leak when you disconnect it.
