Rajan Wilcox
Removing the fuel line from a Harley-Davidson motorcycle can be a challenging task. While there is a wealth of information on Harley forums and Q&A sites, finding clear and concise instructions can be difficult. The process may vary depending on the model and year of the bike, and it is important to take safety precautions when working with fuel. Some steps that may be involved in removing the fuel line include draining the fuel tank, disconnecting hoses and clamps, and removing the fuel pump. It is recommended to consult model-specific instructions or seek advice from experienced mechanics or Harley enthusiasts before attempting any fuel line removal or maintenance.
Harley Fuel Line Removal Process
| Characteristics | Values |
|---|---|
| Fuel Panel Removal | Remove the fuel panel from the top of the tank |
| Hose Removal | Disconnect the hose from the quick disconnect |
| Tank Draining | Drain the tank and remove the clamp |
| Pump Removal | Cut the clamp and remove the pump |
| Quick Disconnect Removal | Unscrew the quick disconnect from the bottom of the tank |
| Hose Setup | Make two hoses shorter than the stock single hose |
| Hose Clamping | Clamp the two hoses to the fuel tank |
| Union Attachment | Attach one side of the 90-degree union to one hose with a clamp |
| Tank Setup | Set up the tank on the frame |
| Union Securing | Attach the other side of the union with another hose clamp |
| Hose Shortening | Shorten the hose lines to avoid hitting the radiator fan |
| Connections | Connect the ground wire, electric connector, and fuel line |
| Hose Clamping for Removal | Clamp the two hoses with hose clamp pliers to reduce gas spill |
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$48.95
What You'll Learn
Remove the fuel panel from the tank
To remove the fuel panel from the tank, you must first drain your tank. This can be done by turning the hex section to the left on both lines, as the upper hexes are hollow and the steel lines pass through them, sealing into check valves at the bottom of the tank. Place a catch pan underneath to collect any remaining fuel.
Once your tank is drained, you can begin to remove the fuel lines. The best way to do this is to pull the crossover line off the front of the tank, but be warned that this can be messy. You can also try breaking the stock hose clamp with diagonal cutters and then removing the two halves of the hose.
When you have removed the hose, you can then remove the pump by cutting and removing the clamp. Finally, the fuel panel can be removed from the tank by unscrewing the quick disconnect from the bottom of the tank.
It is recommended that you replace the other hoses and filters while you have the tank open, unless your bike has less than 25,000 miles on it.
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Drain the tank
To drain the tank of your Harley, you have a few options. Firstly, you can use a siphon hose to drain the fuel into a gas can. This method is simple and effective, but it's important to be careful and avoid any spills or fumes, which can be dangerous.
Another option is to use the fuel pump to empty the tank. You can do this by disconnecting the end of the fuel line that goes to the fuel rail for the injectors and attaching it to a gas can. Then, jump-start the battery to the fuel pump fuse, and it will pump itself empty. Make sure to disconnect the battery once the tank is empty to avoid running the pump for too long without fuel.
If you have a Harley Sportster '07, you can drain the tank by disconnecting the quick coupler on the left side of the tank. Push and hold the outside piece while delicately pulling the line out. Then, remove the fuel pump fuse and connect the bike battery to the fuse terminal with the orange/green wire. This will activate the pump, and the gas will drain out of the quick coupler. Be careful not to over-run the pump once the gas has drained.
For added safety, you can also remove the gas cap on top of the tank to speed up the draining process. Remember to dispose of the drained gasoline responsibly.
Additionally, you can use a tool specifically designed for draining fuel tanks, such as "The Fuel Tool," although this can be expensive. Alternatively, you can create your own tool by using an old fuel line and attaching a long hose to it.
Finally, some people suggest letting the bike run out of gas naturally by starting it and letting it run until the tank is empty. However, this method may not completely empty the tank, and you will need to remove and invert it to get all the fuel out.
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Cut and remove the clamp
To cut and remove the clamp, you will need to first drain your tank. Use a siphon to remove as much fuel as possible. Place a catch pan underneath to collect any spillage. You can also drain the fuel from the set screw on the left line.
Once the tank is empty, you can begin to cut and remove the clamp. Using diagonal cutters or a similar tool, carefully cut the hose clamp. Be sure to protect your hands and eyes when cutting, as there may still be some residual fuel in the line. After cutting, remove the two halves of the hose. With the hose clamp removed, you can now separate the fuel tank from the pump.
It is important to note that some Harley models may have different fuel line configurations, so it is always a good idea to refer to your specific model's service manual for detailed instructions. Additionally, when replacing the fuel line, be sure to use a compatible hose that meets the necessary specifications.
When reinstalling the fuel line, be sure to follow the manufacturer's instructions and take the necessary precautions to avoid any fuel leaks. Ensure all connections are secure and properly tightened before refilling the fuel tank and starting the engine.
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Unscrew the quick disconnect
To remove the fuel line from a Harley, you need to first drain the fuel tank. Place a catch pan underneath to collect any fuel that spills. You can use a siphon to remove as much fuel as possible. Once the tank is drained, you can start to remove the fuel line.
Begin by removing the fuel panel from the top of the tank. You will need to cut and remove the hose clamp, and then remove the pump. Now, you can remove the quick disconnect from the tank by unscrewing it from the bottom of the tank. Be very careful when replacing the quick disconnect not to cross-thread it. It goes in at a bit of an angle, so take care to place a rag underneath when unthreading.
The upper hexes are hollow, and the steel lines pass through them, sealing into check valves at the bottom of the tank. The plug in the bottom of the line is the port to check the fuel pressure. This goes to the fuel pump, and you cannot drain it due to the check valves.
To avoid gas spills, clamp the two hoses with two hose clamp pliers from the auto parts store.
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Remove the two halves of the hose
To remove the two halves of the hose, you will need to first use a siphon to remove as much gas as possible from the tank. Place a catch pan underneath to collect any spillage. Now, you need to break the stock (single-use) hose clamp. You can use diagonal cutters or any other tool of your choice to do this. Be careful when breaking the hose clamp, as you will want to minimize any fuel spillage. Once the hose clamp is broken, you can remove the two halves of the hose.
For the replacement, you can use Gates 5/16" fuel line. It is not necessary to use a fuel injection (45 psi) hose. Make two hoses, each slightly shorter than the stock single hose. Hose clamp these two new hoses to the fuel tank. You can use Norma clamps, which are better than usual as they do not dig into the hose. Instead, the threads grip the hose. Attach one side of the 90-degree union to one hose with a clamp. Now, set up the tank on the frame. Attach the other side of the union with another hose clamp.
You can also finish the setup with the ground wire, the electric connector, and the actual fuel line. To remove the fuel tank, clamp the two hoses with two hose clamp pliers. This will help to reduce the potential for gas spills.
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Frequently asked questions
First, use a siphon to remove as much gas as possible. Then, remove the stock hose and place a catch pan underneath. Cut the hose and drain the fuel. Get the fuel tank on a workbench and use diagonal cutters to break the stock hose clamp. Finally, remove the two halves of the hose.
Remove the fuel panel from the tank on the top, and drain the tank. Cut and remove the clamp, then remove the pump. The quick disconnect can then be unscrewed from the bottom of the tank.
You will need diagonal cutters, or equivalent, and two hose clamp pliers.
Pull the crossover line off the front of the tank, although this can be messy.
Clamp the two hoses with two hose clamp pliers.
