Rajan Wilcox
Removing the fuel pump from a gas tank can be a challenging task, and it's important to do it safely. While it may seem intimidating, removing the gas tank from a Harley-Davidson motorcycle is a relatively straightforward process that is often necessary for various improvements, modifications, and repairs. This process can be made easier by following certain tips and tricks, such as removing parts attached to the lid to create more space, and using specific tools like a cam ring tool or a JIMS Fuel Pump Retainer Remover Tool. It is also important to cover painted areas, drain the fuel from the system, and be cautious when handling the various components to avoid damage.
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What You'll Learn
Removing the cam ring
Firstly, it is important to have the right tools for the job. A cam ring tool is required to remove the cam ring safely. While an official Harley cam ring tool is available, it is reportedly very expensive. Fortunately, a more affordable option is available from Snap-on for $48.
Once you have the correct tool, the first step is to remove the fuel gauge float. This will grant you access to the cam ring, which is located on top of the tank. Using the cam ring tool, carefully take off the cam ring. It is important to do this slowly and carefully to avoid any damage or fuel leaks.
After the cam ring is removed, you will have better access to the fuel pump assembly. At this stage, it is important to be cautious and not use excessive force when pulling out the assembly, as there are many components packed tightly inside the tank. Maneuver the assembly carefully to avoid breaking any parts.
In some Harley models, the bracketry unfolds to allow for easier removal of the fuel pump assembly. Refer to the service manual or a picture guide to identify the spring area, where you can unfold the bracketry by holding the two sides and pulling or tugging. This will provide more space to work with.
By following these steps, you can successfully and safely remove the cam ring from your Harley gas tank, making it easier to access and remove the fuel pump assembly without causing any damage or fuel leaks. Remember to take your time and use the correct tools to ensure a smooth process.
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Disconnecting the fuel lines
First, it is important to cover all painted areas to protect them during the process. Drain the fuel from the system to avoid any spills or leaks. Make sure you have the necessary tools, such as a cam ring tool, to avoid damaging any parts. It is recommended to use a cam ring tool to avoid fuel leaks around the ring if it is not properly in place. You can find affordable options at Snap-On or other tool providers.
Next, locate the two fuel lines that need to be disconnected. Pull up the top plate enough to reach the fuel lines and carefully release them. Take your time and be gentle to avoid any damage or spills. If the fuel lines are difficult to access, you may need to remove the parts attached to the lid to create more space.
Once the fuel lines are disconnected, you will need to manoeuvre the pump assembly carefully to remove it from the tank without damaging any components. It is a tight fit, so take your time and make sure all attached parts are carefully moved out of the way.
If you are replacing the fuel pump, make sure to inspect the fuel lines for any signs of deterioration and replace them if necessary. Harley-Davidson recommends using a new canopy gasket for pre-2008 models and a locking ring gasket for 2008 and newer models.
Finally, remember to take appropriate safety precautions when working with fuel and ensure the area is well-ventilated.
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Taking out the fuel gauge float
To take out the fuel gauge float, you must first remove the cam ring on top of the tank with a cam ring tool. You can use the Snap-On tool, which is more affordable than the Harley cam ring tool. Once you have removed the cam ring, you can then proceed to unplug the wiring.
After that, you can start to finangle the pump assembly out of the tank. It may be easier to remove the parts attached to the lid first so that you have more room to work with. Be careful not to use too much force when pulling out the assembly, as you don't want to break any parts. You may need to manoeuvre the assembly around to get it out without damaging any components.
Another tip is to pull the sender unit down or away from the mounting plate so that it unhinges and swings away to lay flat. This will make it easier to remove the assembly. It is also important to take your time and not rush the process.
Finally, once you have successfully removed the fuel pump assembly, you can then replace the check valve assembly and plug all the hoses and wiring back in before reassembling everything.
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Fishing out the pump assembly
Firstly, it is recommended to remove the fuel lines and the top plate. By pulling up the top plate, you gain access to the fuel lines, which need to be released. This provides more room to work with and makes it easier to manoeuvre the pump assembly out.
Next, you may need to remove any parts attached to the lid, creating more space to fish out the assembly. Be cautious and gentle during this step, as forcing anything may result in breakage.
Now, you can attempt to finagle the pump assembly out of the tank. It might be necessary to carefully wiggle or manoeuvre the assembly to find the right angle to remove it without causing any damage.
If you encounter any issues with the hose or the clamp, as some Harley owners have, you might need to remove the tank entirely to gain better access.
Additionally, for older models, Harley-Davidson provides specific reassembly instructions. For pre-2008 models, the pump should pivot once inside the tank to engage the locking mechanism. Install 10 new canopy bolts and torque them to 18-24 in/lbs in a criss-cross pattern. As for 2008 and newer models, use downward pressure to start the locking ring into the fuel tank, and then use a hammer and a blunt object to drive the locking ring clockwise until the tabs are seated against their stops.
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Using a cam ring tool
To remove the fuel pump from a Harley gas tank, you will need to use a cam ring tool. This is a useful tool to have when removing the fuel pump from your Harley, as it can prevent fuel leaks.
First, you will need to remove the cam ring on top of the tank. A cam ring tool can be purchased for a reasonable price, and it is recommended not to buy the Harley-branded one, as it is overpriced. Once you have the correct tool, removing the cam ring should be easy.
Next, you will need to unplug the wiring. It is advised to remove the fuel gauge float first, then the fuel pump assembly. Be careful not to use too much force when pulling out the assembly, as everything is packed tightly inside. Take it slow and easy, and be mindful of the parts attached to the lid, as you may need to remove them to create more space to work with.
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Frequently asked questions
First, cover all painted areas, drain the fuel from the system, and then use the right tool to remove the pump and filter from the tank. You will have to finangle the pump assembly out of the tank without damaging any components. It may be easier to remove the parts that are attached to the lid first so that you have more room to work with.
You will need to purchase a cam ring tool. Harley sells one, but it is expensive. Snap-on sells one for $48. You will also need a JIMS Fuel Pump Retainer Remover Tool.
You have to pull up the top plate enough to reach in and release the two fuel lines. Then, you will have to maneuver the pump out with everything attached to it. Take it slow and easy.
