Rajan Wilcox
Removing the fuel tank from a Harley Davidson Heritage Softail motorcycle is a complex process that requires careful planning and execution. It is important to have a clean and tidy workspace, with a designated area for the fuel tank and any tools required. Before removing the tank, it is advisable to drain the fuel to reduce the risk of spills and make the tank lighter and easier to handle. This can be done using a fuel valve or a fuel crossover line, with line clamps and rubber plugs to prevent leaks. Once the fuel is drained, the next step is to remove the fuel pump electric plug by locating the locking tab or using a quick-connect fitting. With the fuel system disconnected, the tank can be carefully lifted out, ideally with the help of an assistant.
| Characteristics | Values |
|---|---|
| Fuel tank removal | Remove the fuse for the fuel pump and then try to start the bike |
| Put the tank on a bench, topside up | |
| If the float is attached to the fuel pump bracket, use a long screwdriver to unlock the spring-loaded arm | |
| If there is a fuel crossover tube, clamp it off and remove one side | |
| Have rags ready to wipe up any residual fuel | |
| After draining the tank, unbolt the dash and unplug the electrical connections | |
| Remove the long vent line from the right-side fuel tank and loosen the crossover vent | |
| Remove the hardware that secures the tank to the tank mounts | |
| Pull the tank out and away from the motorcycle |
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What You'll Learn
Prepare your workspace and tools
To prepare your workspace and tools for removing the fuel tank on a Heritage Softail, follow these steps:
Firstly, ensure you have a clean and spacious workspace. It is recommended to have an area of about 4 feet wide on a bench, with a clean towel laid out. If you have access to a motorcycle lift, use it to keep the bike in an upright position. If not, you can perform the task with the bike on the floor. It is also helpful to have an extra pair of hands, so consider asking a friend or assistant for help.
Next, gather the necessary tools and materials. You will need clean rags or towels to wipe up any residual fuel and catch any spills. Have a designated fuel container that is sealed and suitable for storing fuel. If you need to disconnect fuel lines, you will require line clamps and rubber plugs. Additionally, basic hand tools such as screwdrivers, pliers, and a flashlight or torch may be needed.
Before beginning the removal process, it is crucial to drain the fuel tanks. Harley-Davidson fuel tanks have a fuel valve on the left-side tank and a fuel crossover line between the two tanks. You can drain the fuel from the fuel valve or the crossover line. The crossover line provides a quicker drainage option, but ensure you use line clamps and rubber plugs to control the fuel flow.
Once the tanks are drained, you can proceed to the next step, which is to remove the dash. Unbolt the dash and carefully unplug the electrical connections. Always keep the dash in an upright position to avoid damaging any digital displays. At this point, you should also remove the long vent line from the right-side fuel tank and loosen the crossover vent.
Now you have prepared your workspace and gathered the necessary tools, you can proceed with the fuel tank removal process, which will involve carefully removing the hardware that secures the tank to the tank mounts.
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Drain the fuel tank
Before removing the fuel tank on a Heritage Softail, it is important to drain the fuel tank. This will make the tank lighter and easier to handle. There are a few steps to follow to ensure that the fuel tank is properly drained. Firstly, it is recommended to use a motorcycle lift to keep the bike in an upright position. If a lift is not available, the process can also be done with the bike on the floor. It is advisable to have a helper during the removal process.
Next, locate the fuel valve on the left-side fuel tank. This is where the tank can be drained from. To speed up the draining process, you can also use the fuel crossover line between the two tanks, which equalizes fuel levels. When using the crossover line, it is important to use line clamps and rubber plugs to prevent fuel leakage. Have a good, sealed, designated fuel container ready to collect the drained fuel. It is also helpful to have clean rags on hand to wipe up any residual fuel that may escape.
Now, you can begin to drain the tank. Loosen the crossover vent and remove the long vent line from the right-side fuel tank. Once the vent line is removed, you can direct the fuel out of the tanks and into your fuel container. Work quickly and carefully to minimize fuel spillage. Be sure to dispose of any rags that have been soaked with fuel in a safe manner.
Finally, after the tanks are drained, you can proceed with the removal of the fuel tank. Remember to always service your way in and out of every project, inspecting and cleaning areas that are typically hard to access with the tank in place.
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Disconnect the fuel line
Disconnecting the fuel line on a Heritage Softail is a delicate process that requires careful planning and execution. Here is a step-by-step guide to help you through the process:
Step 1: Prepare the Work Area
Before you begin, ensure you have a clean and spacious work area. Have clean rags or towels readily available to wipe up any residual fuel that may escape during the process. It is also recommended to have a designated fuel container to catch any fuel that may spill during the disconnection process.
Step 2: Drain the Fuel Tank
It is essential to drain the fuel tank before removal. Harley-Davidson fuel tanks can be drained from the fuel valve, but they will drain quicker from the fuel crossover line. When draining from the crossover line, use line clamps to pinch off the tube and rubber plugs to prevent fuel leakage. This will ensure that the tank is lighter and easier to handle during removal.
Step 3: Disconnect the Fuel Line
Locate the quick-release fuel line on the left rear bottom of the tank. Use a small screwdriver to carefully loosen and remove the hose clamp that secures the fuel line. Have rags or a bucket and funnel ready to catch any fuel that may spill once the fuel line is disconnected.
Step 4: Remove the Fuel Pump
Place the tank topside up on a bench or stable surface. If your Softail model has the 'float' attached to the fuel pump bracket (common in pre-2006 Softails), you will need to use a long screwdriver to unlock the spring-loaded arm. Insert the screwdriver into the tank and carefully push against the arm to unlock the bracket. Then, slowly remove the fuel pump from the tank.
Step 5: Handle Residual Fuel
Even after draining the tank, some fuel may remain. As soon as you remove the fuel line, be prepared for fuel to start pouring out of the tank. Have rags or a bucket and funnel ready to catch the fuel and prevent it from spilling onto the ground or other motorcycle components. Ensure that any rags soaked with fuel are disposed of safely.
By following these steps, you can successfully disconnect the fuel line on your Heritage Softail. Remember to work carefully and have a helping hand nearby to make the process smoother and safer.
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Remove the fuel pump
To remove the fuel pump, first, ensure that your Harley Davidson Softail is in an upright position, preferably on a motorcycle lift. If you do not have access to a lift, you can lay the bike on its side, but be cautious to avoid any fuel spillage. It is recommended to have a helper when removing the tank.
Next, you will need to remove the fuel line on the quick-release located on the left rear bottom of the tank. If your bike is equipped with a fuel crossover tube, you will need to clamp it off and remove one side to access the wiring. Be prepared for fuel to start pouring out once the tube is disconnected, so have rags and a bucket ready to catch the fuel.
Now, you can focus on the fuel pump itself. Place the tank on a bench with the top side up. Inspect the fuel pump bracket to determine if it has a 'float' attached (common on pre-2006 Softails). If so, use a long screwdriver to unlock the spring-loaded arm by carefully pushing against it. This will allow you to release the bracket and lay the pump flat for removal. Some tanks do not require unlocking the arm, so if you cannot release it, proceed to the next step.
Finally, slowly pull out the fuel pump from the tank. Be cautious as some fuel may still be present in the tank or lines.
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Lift the tank away from the motorcycle
When removing the fuel tank from a Harley-Davidson Softail, it is important to take precautions to avoid spilling fuel. Firstly, ensure that the motorcycle is in an upright position, either using a motorcycle lift or by having someone hold it steady. If your Softail has a two-piece fuel tank, you will need to drain the fuel tanks before removal. This can be done through the fuel valve or, for quicker drainage, through the fuel crossover line using line clamps and rubber plugs.
Once the tank is drained, you can begin the removal process. If your Softail has a quick-release fuel line, undo the line on the left rear bottom of the tank. If not, you may need to use a small screwdriver to remove the hose clamp. Be prepared for fuel to start leaking from the tank once the hose is removed. Have rags and a bucket ready to catch the fuel.
Now, you can carefully lift the tank away from the motorcycle. It may be helpful to have an extra set of hands for this step. Place the tank topside up on a clean bench or table to avoid making a mess. Be sure to also remove the pump from the tank using a screwdriver to unlock the spring-loaded arm if necessary.
Overall, removing the fuel tank from a Harley-Davidson Softail requires careful planning and preparation to avoid spilling fuel. By following these steps, you can safely and effectively remove the fuel tank from your motorcycle.
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Frequently asked questions
Here is a step-by-step guide to removing your fuel tank:
- Drain the fuel tank.
- Remove the fuse for the fuel pump and then try to start the bike to release pressure.
- Disconnect the fuel line from the quick-release valve.
- Remove the dash and unplug the electrical connections.
- Remove the vent line from the right-side fuel tank and loosen the crossover vent.
- Remove the hardware that secures the tank to the tank mounts.
- Carefully pull the tank out and away from the motorcycle.
You will need a tube clamp, a small screwdriver, rags, and a bucket or funnel to catch any fuel that may leak. You may also need a long screwdriver to unlock the spring-loaded arm if your fuel pump bracket has a 'float' attached.
Yes, it is important to drain the fuel tank before removal to avoid spills. You should also have rags on hand to wipe up any residual fuel and dispose of them safely. Additionally, be sure to never leave the dash upside down as it can damage the digital display.
