Regan Brown
If you're looking to replace a Softail fuel tank access gasket, you've come to the right place. This guide will take you through the process step-by-step, from carefully cutting away the fuel pump line to trimming any excess gasket for a seamless finish. You'll also learn how to properly secure the Torx bolts and pop the Harley logo into place to cover the top hold-down bolt. By following these simple steps, you'll be able to give your Softail a brand-new look.
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What You'll Learn
Removing the old console
To remove the old console, you'll need to carefully cut away the fuel pump line from the old console and set the console aside. You can then trim any excess gasket away for a nice finish.
When removing the old console, it's important to note that you may not need to disconnect the harness from under the tank. There may be enough slack in the wire to pull up the fuel gauge and get the old gasket off. However, if the old gasket is brittle and broken, it may be easier to simply disconnect the harness and remove the tank fasteners to move the tank back.
Once the old console is removed, you'll want to place the new console into position for correct fitment before making any connections permanent. Ensure that there are no gaps between the console and the tank when installing the top Torx bolt, and then secure the lower Torx bolts.
Finally, pop the Harley logo into place to cover the top hold-down bolt.
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Trimming excess gasket
To trim excess gasket, you'll first need to carefully cut away the fuel pump line from the old console. Set the console aside, and place the new console into position, ensuring a correct fitment.
Now, you can trim any excess gasket away. Take care to push down on the lower end of the console as you install the top Torx bolt, ensuring there are no gaps between the console and the tank.
Secure the lower Torx bolts, and pop the Harley logo into place to cover the top hold-down bolt.
Reinstall the driver's seat, followed by the passenger seat, and admire your handiwork!
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Using a screwdriver to remove the old gasket
To replace the fuel gauge gasket on a Softail, you will need to disconnect the harness from under the tank. However, some people have found that there is enough slack in the wire to pull up the fuel gauge and get the old gasket off without disconnecting the harness.
To remove the old gasket, you can use a screwdriver. Place the screwdriver blade at a 30-degree angle and slide the bottom of the blade under the centre of the old gasket. Gently tilt the screwdriver to lift the old gasket out of its cavity. Be careful not to damage the threads on the cap, as this will make it difficult to install the new gasket.
Once the old gasket is removed, you can work the new gasket over the top of the gauge. Trim any excess gasket away for a nice finish. Secure the Torx bolts and pop the Harley logo into place to cover the top hold-down bolt.
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Pushing up on the wire from the bottom of the tank
The first step is to carefully cut away the fuel pump line from the old console and set the console aside. You can then place the new console into position for correct fitment before making any connections permanent. When installing the top Torx bolt, it is important to push down on the lower end of the console to ensure there are no gaps between it and the tank.
At this point, you can push up on the wire from the bottom of the tank while gently pulling up on the gauge. This will give you enough slack in the wire to get the gauge entirely out of its cavity.
Once you have removed the old gasket, you can work the new gasket over the top of the gauge. This is a much simpler method than the manual instructions, which involve removing all tank fasteners and moving the tank back.
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Installing the new gasket
To install the new gasket, you'll need to place the new console into position for correct fitment before you start making connections permanent. You'll then want to trim any excess gasket away for a nice finish. When installing the top Torx bolt, push down on the lower end of the console to ensure there are no gaps between it and the tank. Secure the lower Torx bolts.
If you're replacing a fuel filler cap gasket, set the new gasket down on the insert and use a small flat-tip screwdriver to gently press it down evenly all around. A properly fitting gasket will fit nicely in the groove. Place the insert on the fount or tank. Then place the filler cap over the insert and turn it until it just starts getting tight. Now you can take the centre screw and install it. When the screw begins to get tight and you feel the insert starting to turn, tighten the cap down as much as you can with your fingers. Re-tighten the centre screw until tight.
If you're replacing a fuel gauge gasket, you can push up on the wire from the bottom of the tank while gently pulling up on the gauge. There should be enough slack in the wire to get the gauge entirely out of its cavity. You can then work the new gasket over the top of the gauge.
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Frequently asked questions
No, there is enough slack in the wire to pull up the fuel gauge and get the old gasket off.
The old gasket should be brittle and broken, so getting it off shouldn't be a problem.
You can work the new gasket over the top of the gauge.
No, this is not necessary.
Trim any excess gasket away for a nice finish.
