Sylvie Willis
Removing the fuel tank from a Harley Softail can be a tricky process. It is important to prepare a clean, spacious area to work in and to have the necessary tools and materials ready. The first step is to disconnect the battery and fuel line, taking care to avoid spillage. Next, loosen the bolts at the front and rear of the tank, and remove any trim pieces or seat coverings. Depending on the model, you may need to remove the instrument cluster and disconnect additional components such as the throttle body and breather tube. With the tank bolts removed, carefully lift the tank, being mindful of any attached fuel lines or hoses. Finally, place the tank in a safe location and complete any necessary repairs or modifications before reinstalling it.
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What You'll Learn
Disconnect the battery and fuel line
Disconnecting the battery and fuel line is a crucial step in removing the fuel tank from a Harley Softail. Here is a detailed guide to help you through the process:
Disconnecting the Battery:
Before beginning any work on your Harley Softail, it is essential to disconnect the battery. This is a safety precaution to prevent any electrical issues or accidents during the fuel tank removal process. Locate the battery and disconnect the negative terminal first, followed by the positive terminal. Ensure that you have the necessary tools, such as wrenches or screwdrivers, to safely disconnect the battery terminals.
Disconnecting the Fuel Line:
The next critical step is to disconnect the fuel line from the fuel tank. This process can vary slightly depending on the model year of your Harley Softail, but the basic principles remain the same. First, locate the fuel line quick disconnect, typically found on the left-hand side of the bike. For most Softail models, this quick disconnect is made of plastic, so be gentle to avoid cracking it. Pinch the crossover fuel line at the end of each nipple using needle-nose vise grips, but take care not to pinch the nipples themselves.
Draining the Fuel:
Before proceeding further, it is essential to drain the fuel from the tank to make the removal process safer and less messy. Siphon or pump out as much fuel as possible to speed up the draining process. Place a fuel can near the bike, cut the crossover fuel line in the center, and use a flexible hose to direct any remaining fuel into the container. Repeat this step for both sides of the crossover fuel line.
Finalizing Fuel Line Disconnection:
With the fuel drained, you can now finalize the disconnection of the fuel line. Loosen the bolts at the front and rear of the fuel tank, being mindful that they may also be holding the trim piece in place. You may need to remove the instrument cluster and the front and rear tank bolts to fully access the fuel line. Once the bolts are loosened, carefully detach the fuel line from the throttle body, ensuring you don't crack the barbed end of the disconnect fitting.
Safety is paramount when working on your Harley Softail, so always refer to the factory service manual for specific instructions and illustrations related to your motorcycle's model year. Additionally, having a helper during this process can make it easier to manage the fuel line and tank removal safely and efficiently.
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Drain the fuel
To drain the fuel from your Harley Softail, you will need to expose the fuel lines. This can be done by pulling up the rubber skirt under your gas cap. Locate the fuel out line, which can be identified by its blue tabs. Pinch the tabs to remove the line, then push on a suitable hose and insert the other end into a container to catch the fuel.
Next, you will need to locate and remove the fuel pump fuse. This can be done by taking the seat and side cover off the bike. With the fuse removed, you can now attach a jumper wire from the fuse terminal to the positive battery terminal. This will turn on the fuel pump, allowing you to drain the fuel.
It is important to note that you should always exercise caution when working with fuel. Ensure that you keep your fuel lines clean and are mindful of any potential fire hazards. Working outdoors or in a well-ventilated area is recommended.
Additionally, if your Harley Softail is equipped with a \"Petcock\" shut-off valve, you can turn it off before attaching a "fuel-safe" hose from the valve to a gas can. This will allow you to drain the fuel directly into the container.
Another method to drain the fuel is to disconnect the fuel line from the throttle body. By doing so, you can then route the fuel line to a gas can and jump the battery to the fuel pump fuse, causing the pump to empty.
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Loosen bolts at the front and back of the tank
Loosen the bolts at the front and back of the tank. Before you do this, disconnect the fuel line to the throttle body. It is a plastic quick disconnect, and if you skip this step, you may crack the barbed end of the disconnect fitting. You can then remove the bolts at the front and back of the tank. You may find that the same bolts are holding the trim piece in place, or at least get a better idea of what is holding it in place.
If your Harley Softail is a 2006 model or older, you will need to remove the instrument cluster, the front tank bolt, and the rear tank hex bolt after removing the seat. However, if you have a newer model, the process is slightly different. You will need to undo the fuel line on the quick-release located on the left rear bottom of the tank. This will vary depending on the make and model of your Harley Softail, so it is recommended to refer to a factory service manual for specific instructions.
It is also important to note that some steps in the tank removal process may require an extra set of hands, so it is advised to have an assistant to help you with the removal. Additionally, if you have access to a motorcycle lift, this will make the process easier as it will keep the bike in an upright position. Alternatively, you can perform the tank removal while the bike is on the floor.
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Remove the fuel pump
To remove the fuel pump from a Harley Softail, you will first need to remove the fuel tank. This process should work for all Softails, Dynas, and Dressers, but some steps may vary. Here is a step-by-step guide:
Remove the Fuel Tank:
- Drain the gas from the tank to avoid spillage.
- Disconnect the fuel line to the throttle body. Be careful not to crack the barbed end of the disconnect fitting.
- Remove the bolts at the front and back of the tank.
- Disconnect the fuel line on the quick-release located on the left rear bottom of the tank.
- Slowly slide the tank back until you can access the fuel pump.
- Place the tank on a bench with the top side up.
- If your Harley Softail is a 2006 model or older, the 'float' is likely attached to the fuel pump bracket. In this case, use a long screwdriver to unlock the spring-loaded arm by pushing against it. Then, lay the pump flat and slowly bring it out of the tank.
- If you cannot unlock the arm, this means that your tank does not require you to do so. Simply remove the fuel pump and sending unit.
- Remove the two fuel lines that are connected to the fuel pump assembly.
- Maneuver the fuel pump assembly out of the tank, being careful not to use too much force and break any parts.
- Install a new fuel pump assembly, if necessary, and reverse these steps to reinstall the fuel tank.
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Clean up any spills
When removing the fuel tank from a Harley Softail, it is important to clean up any fuel spills to avoid damage to the motorcycle and for safety reasons. Here are some detailed steps and tips to effectively clean up fuel spills:
Prepare a clean area for the task: Set up a workspace that is well-ventilated and has a clean surface to place the fuel tank and its components. Cover the workbench with a clean towel or a cardboard box to catch any drips or spills. Having a clean and organised workspace will make it easier to manage any spills that may occur during the process.
Prevent spills during tank removal: Before lifting the fuel tank, it is important to disconnect the fuel line from the throttle body. Make sure to use a plastic quick disconnect to avoid cracking the barbed end of the fitting. Additionally, follow the steps outlined in the Harley Softail manual or seek guidance from online resources to minimise the risk of spills during the tank removal process.
Manage spills with proper techniques: If fuel spills occur, use absorbent materials such as towels or rags to soak up the spilled fuel. Have a suitable container, such as a gas can, nearby to collect the spilled fuel. If fuel has spilled onto the motorcycle's surfaces, use dish soap and water to clean it off as soon as possible. Avoid leaving the fuel to air dry, as it can damage the paint, plastic, and rubber parts of the motorcycle.
Dispose of spilled fuel properly: Ensure that the spilled fuel is disposed of responsibly and in accordance with local regulations. Do not pour it down the drain or into the environment. Take the collected fuel to a designated hazardous waste disposal facility or recycling centre.
Inspect and maintain the fuel system: After cleaning up the spills, inspect the fuel lines, connections, and fuel tank for any leaks. Regularly maintain your motorcycle's fuel system according to the recommended maintenance schedule. This includes inspecting and replacing fuel filters, cleaning fuel injectors or carburetors, and ensuring the fuel quality meets the recommended standards.
By following these steps and maintaining a clean and organised workspace, you can effectively clean up and manage any fuel spills that may occur during the removal of the fuel tank from your Harley Softail. Remember to prioritise safety and proper disposal of hazardous materials at all times.
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Frequently asked questions
Here are the steps to remove the fuel tank from your Harley Softail:
- Disconnect the battery.
- Disconnect the fuel line at the quick disconnect.
- Drain the fuel.
- Loosen the bolt at the front and rear of the tank.
- Remove the tank.
Yes, it is recommended to drain the fuel before removing the tank to avoid spillage. You can do this by siphoning or pumping out the gas and then pinching and cutting the crossover fuel line.
You will need a few tools for the job, including a pair of needle-nose vise grips, a flexible hose, a fuel can, and a long screwdriver.
Yes, it is important to be careful when working with fuel and to have a helper if possible. It is also recommended to have a clean work area and to protect any sensitive components, such as the rockers, with a piece of cardboard.
