Replacing Softail Fuel Tank Access Gasket: Step-By-Step Guide

Replacing a Softail fuel tank access gasket is a complex process that requires careful attention to detail. The procedure involves multiple steps and a range of tools, including screwdrivers, wrenches, and torx head ratchets. It is important to note that the fuel tank should be drained and the battery disconnected before beginning the replacement process. Additionally, it is recommended to work in a well-ventilated area due to the presence of harmful fumes. The steps outlined in the relevant sources provide a comprehensive guide to replacing a Softail fuel tank access gasket, ensuring a smooth and safe process.

Prepare your bike and work area

Before you begin, make sure you have all the necessary tools and safety equipment. This includes things like a torque wrench, screwdrivers, a fuel drain pan, and safety goggles. It's also important to work in a well-ventilated area to avoid inhaling harmful fumes.

Park your bike on a flat surface and engage the side stand. Make sure the engine is cool to the touch before beginning any work. Place a piece of cardboard or a drip pan underneath the bike to catch any fuel spills or leaks.

Remove the seats for better access to the fuel tank. This will usually involve removing a few bolts or knurled fasteners. Be gentle and set the seats aside in a safe place.

Now, disconnect the battery. Safety is key, so always remove the negative cable first. This will prevent any electrical shorts or potential fire hazards while you work on the fuel system.

Prepare the Work Area

Lay out all the tools you'll need within easy reach. This includes the new fuel tank access gasket, a torque wrench, screwdrivers, a fuel drain pan, safety goggles, and gloves. Having a clean and organised work area will make the process smoother and help you avoid losing any small parts.

If you have access to a motorcycle lift, now is the time to use it. Lift the bike to an upright position, making it easier to access the fuel tank and related components. If you don't have a lift, you can carefully tilt the bike onto its side stand to access the fuel tank.

Drain the tank

Before you begin, ensure your Harley Davidson is on a flat surface. Safety is paramount, so avoid smoking or using open flames.

To drain the tank, you'll need to empty the fuel into a drain pan. Here's a detailed breakdown of the process:

• Undo the Fuel Line: First, undo the fuel line on the quick-release located on the left rear bottom of the tank. This will allow you to drain the fuel.
• Prepare a Funnel and Bucket: Have a funnel and a large bucket ready to collect the fuel.
• Loosen the Connector: Loosen the quick-release connector on the lower left of your tank with a wrench. Just loosen it enough so that fuel starts to come out.
• Drain the Fuel: Once fuel begins to flow, be ready with your funnel and bucket to collect it. Drain as much fuel as possible from this connector. If your bike is secure, you can shake the tank gently to get out any remaining fuel.
• Hand-Tighten the Connector: After draining, hand-tighten the connector to prevent any more fuel from coming out. You may need to use your wrench for this step.
• Front Crossover Line: Now, move to the front crossover line. Attach a 3-foot piece of hose (with the same diameter as your stock crossover line) and a 3/8" bolt. Remove the clamp on the left side, just as you did for the pump hose.
• Cover the Open End: As you remove the hose, quickly cover the open end of the crossover line with your finger, and attach the other end of the 3-foot fuel line to it. Guide the fuel into your fuel can.
• Drain the Crossover Line: Get as much fuel as possible out of this fitting. Keep your finger over the open end to avoid spills.
• Plug the Crossover Line: Once you've drained the left side, remove the 3-foot fuel line and add one of the vacuum plugs to the crossover line to prevent leaks.
• Repeat for the Right Side: Repeat the process for the right side of the bike. Loosen the right tank fitting clamp, remove the right side of the crossover line, and attach your 3-foot line to drain the fuel.
• Final Draining: After draining the right side, remove the line and add the second vacuum plug. At this point, you should have removed about 95% of the fuel from the tank.

Now that the tank is mostly drained, you can proceed to the next steps of removing the fuel tank and replacing the gasket.

Disconnect the battery

Disconnecting the battery is an important step when working on your Harley-Davidson Softail. It is a safety precaution that can prevent electrical shorts and potential fire hazards. Here is a detailed guide on how to disconnect the battery:

Step 1: Locate the battery. To access the battery on a Harley-Davidson Softail, you will need to remove the seat. Remove the fastener at the rear of the seat and slide it rearward to free it from the bike. If your bike has a seat strap, you may need to remove it before taking off the seat.

Step 2: Expose the battery. Underneath the seat is the ECM (Engine Control Module) plate, which needs to be removed to access the battery. Use a T40 Torx fastener to loosen and remove the ECM plate. If your bike has a security system, carefully slide the antenna off the plate before removing it.

Step 3: Disconnect the negative cable. With the ECM plate removed, you will now have access to the battery. Locate the negative (-) cable, which is usually black and marked with a "-" symbol. Disconnect the cable from the battery terminal. You may need to loosen a clamp or bolt to do this. Ensure that you do not disconnect the positive cable, as this can cause electrical issues.

Step 4: Secure the battery. Once the negative cable is disconnected, you can move the battery to a secure location away from the bike. Make sure it is placed in an upright position and cannot tip over. Covering the battery terminals with tape or insulated caps can provide additional protection against accidental contact.

Step 5: Work safely. With the battery disconnected, you can now proceed with other maintenance or repair tasks on your Harley-Davidson Softail. Remember to work in a well-ventilated area and wear appropriate safety gear, such as gloves and eye protection. Always refer to the service manual for your specific model for additional safety precautions and guidelines.

Step 6: Reinstall the battery. After completing your work on the bike, you will need to reconnect the battery. Ensure that the battery is charged and in good condition before reconnecting. Follow the previous steps in reverse, making sure to connect the negative cable last. Tighten all connections securely and ensure that the battery is mounted firmly in place.

Remember, working with batteries and electrical systems can be dangerous. Always exercise caution and refer to the specific instructions for your Harley-Davidson Softail model. If you are unsure about any part of the process, it is best to consult a qualified mechanic or seek advice from a Harley-Davidson forum or specialist.

Remove the seats

To remove the seats from your Harley-Davidson Softail, you will need to gather the right tools for the job. These include a flat-head screwdriver and a Torx head ratchet with various-sized Torx bits, including T25, T27, T35, and T40. Optionally, you can also have a wrench or socket set and an Exacto knife or another razor-sharp bladed knife. Shop rags or painter's tape will also come in handy.

Now, let's get started with the step-by-step process:

• Remove the Passenger Seat (if applicable): If your Softail has a passenger seat, start by removing it. Typically, you can do this by simply unscrewing the bolts holding it in place. In some cases, these may be knurled fasteners that you can remove with your fingers.
• Remove the Rear Seat: Locate the single bolt on the rear fender, which is usually found behind the passenger seat. Remove this bolt and then pull the rear seat straight out.
• Remove the Driver's Seat: With the rear seat removed, the mounting bolts for the driver's seat will be exposed. Remove these two bolts and carefully lift the driver's seat off. On some models, there may be a nut and stud instead, so make sure to note this before proceeding. To make reassembly easier, consider putting the nut or bolt back in place temporarily to keep the mating piece from falling out.
• Reassembly Tip: When putting the seats back on, remember to tighten the bolts securely to ensure the seats are firmly attached to the bike. This will help prevent any unwanted movement or vibrations while riding.

By following these steps, you will have successfully removed the seats from your Harley-Davidson Softail. Remember to keep your workspace organized and have a safe and well-lit environment to work in. If you're working with a helper, communicate clearly to avoid any mishaps. Now, you can continue with the next steps of your fuel tank access gasket replacement or any other modifications you have planned.

Take off the fuel lines

To take off the fuel lines, you will need a small flat-blade screwdriver and a wrench.

First, undo the fuel line on the quick-release connector located on the left rear bottom of the tank. You will need to use your small flat-blade screwdriver to loosen the clamps. Once the clamps are loose, remove the hose from the pump. Be careful not to poke a hole in the hose when you are loosening the clamp. If you carefully insert your small screwdriver into the very end of the hose, this will loosen it up enough that you can pull it off by hand.

Next, use your wrench to loosen the quick-release connector on the lower left of your tank. Loosen it until fuel starts coming out. Be sure to have a funnel and a large bucket ready to catch the fuel. Drain as much fuel as you can from this connector. If your bike is secure, once the fuel stops coming out, you can shake the tank to get a little more fuel out. Now, hand-tighten the connector to prevent any more fuel from coming out. You may need to use your wrench to do this.

Now, go to the front crossover line. Have a 3-foot piece of hose ready to attach (the same diameter as the stock crossover line). Remove the clamp on the left side in the same way you did for the pump hose. Once the clamp is loose, quickly remove the hose and cover the open tank fitting with your finger. Be sure to have the other end of the 3-foot piece of hose leading into the fuel can. Get as much fuel as you can out of this fitting. Keep your finger over the open end of the crossover line. This needs to be done quickly to avoid a mess.

Finally, go to the right side of the bike. Loosen the right tank fitting clamp and remove the right side of the crossover line. Quickly put on your 3-foot piece of hose and drain the fuel. Once drained, remove the line and add a vacuum plug.

Now you have successfully taken off the fuel lines and can move on to the next steps of replacing your Softail fuel tank access gasket.

Frequently asked questions