Rajan Wilcox
Removing the fuel tank from a 2001 Dyna Super Glide may seem intimidating, but it's a straightforward job that can be accomplished at home. It is much easier if the bike is low on fuel. The fuel tank on a Harley Davidson Dyna model has to be removed to install various modifications and to fix mechanical or electrical issues. The process has become less intuitive since 2006, when all Harley Dyna Models were equipped with the closed-loop, Delphi electronic fuel injection.
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What You'll Learn
Relieve fuel system pressure and disconnect the battery
To relieve the fuel system pressure on a 2001 Dyna Super Glide, first, remove the fuse box cover located below the seat on the left side of the motorcycle. Then, locate and remove the fuel pump fuse. With the fuel pump fuse removed, crank the engine over. The engine may start and run for a few seconds before it runs out of fuel and dies.
Now, to disconnect the battery, shift the bike into neutral and start the engine. Wait for the engine to die and try to start the bike for another five seconds. To prevent the possibility of an accidental short and a potential fire hazard, disconnect the battery.
It is important to note that the fuel lines maintain pressure even when the bike is off. Thus, relieving the fuel system pressure and disconnecting the battery are crucial steps before proceeding with fuel tank removal.
Once the pressure is relieved and the battery is disconnected, you can move on to the next steps of removing the fuel tank. This may include disconnecting the fuel supply line, fuel gauge wiring harness, and crossover fuel line, as well as draining the remaining fuel from the tank. These steps should be approached with caution to prevent any fuel leaks or spills.
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Disconnect the fuel supply line
Disconnecting the fuel supply line is a crucial step in removing the fuel tank from a 2001 Dyna Super Glide. Here is a detailed, step-by-step guide on how to safely and effectively complete this task:
Firstly, locate the fuel supply line. It is connected to the fuel tank and is responsible for supplying fuel to the engine. Before disconnecting any lines, it is important to relieve the fuel system pressure to avoid any accidental spills or high-pressure fuel spray. This can be done by removing the fuel pump fuse, which is located in the fuse box on the left-hand side of the motorcycle, below the seat.
Once the fuel pump fuse is removed, crank the engine to release any remaining pressure. You may notice that the engine starts and runs for a few seconds before dying out, which is normal. To prevent any potential safety hazards, it is important to disconnect the battery at this stage.
Now, you can proceed with disconnecting the fuel supply line. Place a shop rag underneath the connection to catch any residual fuel that may leak out. Grasp the quick-connect sleeve of the fuel supply line and lift it up, while simultaneously pulling down on the fuel line to detach it from the tank. This step requires a gentle touch to avoid any damage to the connection or the fuel line itself.
In some models, you may need to use two small flat-head screwdrivers to pry out the fuel pump fuse. Additionally, ensure you have a gas can ready to catch any fuel that drains from the tank during this process.
By following these steps, you can safely disconnect the fuel supply line from your 2001 Dyna Super Glide, making it possible to remove the fuel tank for maintenance, repairs, or modifications. Remember to exercise caution and refer to the specific model's manual if you have any doubts during the process.
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Drain the fuel tank
To drain the fuel tank of a 2001 Dyna Super Glide, you must first relieve the fuel system pressure and disconnect the battery. This is done by removing the fuel pump fuse, which is located in the fuse box on the left-hand side of the motorcycle, just below the seat. With the fuel pump fuse removed, crank the engine over—it may start and run for a few seconds before dying.
Next, you will need to disconnect the fuel supply line. Do this by lifting up on the quick-connect sleeve and pulling down on the fuel line. You will also need to disconnect the fuel gauge wiring harness on the left underside of the tank.
Now, using a funnel, hose, and suitable catch can/gas can, disconnect the crossover fuel line at the front of the tank. It is important to pinch the disconnected side of the line to prevent spills and allow the fuel to drain into the gas can.
You can also use a set of vice-grips to pinch the fuel line and block the flow of fuel, providing further protection against spills. This step is especially important if your bike has fuel injection (EFI), as it prevents the possibility of high-pressure fuel spray.
Finally, with the fuel tank removal process complete, carry the tank to a well-ventilated location and allow it to air out.
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Remove the fuel gauge wiring harness
Removing the fuel tank from a 2001 Dyna Super Glide can be done at home and is quite simple, although it can be a bit unnerving as the tank is one of the most cosmetically important parts of the bike and can be easily scratched or dented.
To remove the fuel gauge wiring harness, first relieve the fuel system pressure and disconnect the battery. Disconnect the fuel supply line by lifting the quick-connect sleeve and pulling down on the fuel line.
Now, you can disconnect the fuel gauge wiring harness on the left underside of the tank. Using a funnel, hose, and suitable catch can/gas can, disconnect the crossover fuel line at the front of the tank. Pinch the disconnected side of the line, allowing the fuel to drain from the tank.
Before disconnecting the wiring, take note of how the plug is wired. There are three wires: orange, black, and yellow. The orange wire is +12V, the black is ground, and the yellow wire sends the signal for the gas gauge function. Use a small electrical pick to remove the wires from their plug, being careful not to pull too hard. If you feel resistance, stop and reassess.
You can use a paper clip or a pin to disconnect the wires from the plug, as per the service manual.
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Remove the tank and carry it to a well-ventilated location
Removing the fuel tank of a 2001 Dyna Super Glide can be intimidating, but the process is quite simple and straightforward. Before removing the tank, it is recommended to ride the bike until the fuel level is low. This will make the process easier and reduce the risk of spills. Here is a step-by-step guide to removing the fuel tank and carrying it to a well-ventilated location:
Preparation:
First, locate and remove the fuse box cover on the left side of the motorcycle, just below the seat. Remove the fuel pump fuse to relieve the fuel system pressure. With the fuel pump fuse removed, crank the engine and let it run until it dies. Disconnect the battery to prevent any accidental shorts or fire hazards.
Draining the Fuel:
Place a suitable catch can or gas can below the fuel tank to catch any remaining fuel. Disconnect the fuel supply line by lifting the quick-connect sleeve and pulling down on the fuel line. Use a funnel and hose to drain the fuel completely. Allow the fuel to drain into the gas can.
Removing the Tank:
Loosen and remove the front and rear mounting bolts, washers, and nuts under the tank with an open-end wrench. Pull the fuel gauge connector apart. Remove the tank by lifting it straight up.
Carrying to a Well-Ventilated Location:
Carry the removed fuel tank to a well-ventilated area, away from any open flames or sparks. Ensure the area is safe and free from potential ignition sources. Allow the tank to air out completely before proceeding with any maintenance or modifications.
Always exercise caution when handling fuel, and ensure proper ventilation to prevent the buildup of flammable vapors.
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Frequently asked questions
Here is a step-by-step guide to help you with the process:
- To prevent high-pressure fuel spray, purge the fuel system pressure.
- Remove the fuse box cover located under the seat on the left side of the motorcycle.
- Locate and remove the fuel pump fuse.
- Crank the engine over and let it run until it dies.
- Disconnect the battery to prevent a potential fire hazard.
- Disconnect the fuel supply line by lifting the quick-connect sleeve and pulling down on the fuel line.
- Disconnect the fuel gauge wiring harness on the left underside of the tank.
- Drain the fuel into a gas can by disconnecting the crossover fuel line.
- Reach under the tank and pull up on the fuel tank fitting while pulling down on the fuel line.
- Unscrew the acorn nut in the middle of the instrument panel and remove the panel.
- Pull apart the plug and socket ends of the fuel pump module connector.
- Remove the tank by lifting it straight up and carrying it to a well-ventilated area.
No, you don't need any specialised tools. You can use common tools like screwdrivers, wrenches, and a funnel to help with the process.
While it may seem intimidating at first, removing the fuel tank from your Dyna Super Glide is a straightforward process that can be accomplished at home with care and a soft touch.
Removing the fuel tank is necessary for installing modifications, diagnosing issues, and performing maintenance on your Dyna Super Glide. It provides access to various mechanical and electrical components.
Yes, it is important to ensure that the fuel system pressure is relieved and the battery is disconnected before removing the fuel tank. Always use a shop rag to catch any leaking fuel and work in a well-ventilated area.
