Replacing Fuel Lines: 97 Road King Maintenance Guide

If you're looking to replace the fuel lines on your 97 Road King, you've come to the right place. This is a complex task and you should be prepared for a challenge, especially when it comes to removing and replacing the canopy. You'll need to start by draining the fuel tank through the crossover hose at the front of the tank. Be warned, this will be messy! You'll then need to disconnect the power to the fuel pump and start the bike, operating the starter for a few seconds to remove remaining fuel. Next, you'll need to disconnect the negative battery cable, remove the console from the canopy, and then the canopy itself by removing the 10 Torx screws securing it to the tank. You'll then need to lift the canopy and remove the yellow wire from the inboard side. Now for the tricky part: inside the tank, you'll need to lift the fuel pump isopod off the two posts and cut the clamp from the tubing at the pump outlet. You can then remove the black and yellow wires from the pump and replace as necessary. Reassembly is then the reverse of the removal process. Good luck!

Drain the fuel tank

To drain the fuel tank of your 1997 Road King, follow these steps:

Firstly, remove the seat to access the fuel tank. Next, drain the fuel from the tank. You can do this by removing the crossover hose at the front of the tank and letting the fuel drain out, or by blocking off the crossover lines and leaving the fuel in the tank. Be careful, as fuel will be flying everywhere!

Once the tank is drained, you can move on to purging the fuel system. Disconnect the power to the fuel pump at the connector in front of the battery, and start the bike. When the engine stalls, operate the starter for about three seconds to remove any remaining fuel. Now you can disconnect the negative battery cable.

At this point, you can remove the console from the canopy, and then the canopy itself. For the 1999 model, this is done by removing 10 T-20 torx screws securing the canopy to the tank. You will then need to slightly raise the canopy and remove the yellow wire from the spade contact on the inboard side.

Now, you can access the inside of the tank. Lift the fuel pump isopod off the two posts inside the tank. Cut the clamp from the tubing at the pump outlet and disconnect the tubing. Finally, remove the black and yellow wires from the pump.

You have now successfully drained and removed the fuel pump from your 1997 Road King's fuel tank. Remember to work carefully and stay safe!

Disconnect the negative battery cable

Disconnecting the negative battery cable is one of the first steps to take when replacing the fuel lines on a 97 Road King. Here is a detailed, step-by-step guide on how to do this:

First, locate the negative battery cable. It is usually black and connected to the negative terminal of the battery, which is often marked with a "-" sign. Once located, proceed to the next step.

Before disconnecting the cable, it is important to take necessary safety precautions. Put on safety goggles and gloves to protect your eyes and hands from any potential battery acid spillage. Now, place a clean and dry cloth around the battery to catch any spillage and have a small container or bowl ready to collect any excess battery acid.

With safety measures in place, you can now begin the disconnection process. Using an appropriate-sized wrench or socket, loosen the negative battery cable clamp bolt by turning it in a counter-clockwise direction. Do not allow the wrench or socket to touch any other parts of the bike, especially metal components, as this could result in an accidental short circuit. Once the bolt is loose, carefully lift and remove the cable from the battery terminal. Ensure that the cable does not touch any metal parts of the bike during this process.

After the cable is disconnected, secure it away from the battery and any metal components to prevent accidental contact. You can use cable ties or zip ties to keep it in place. Additionally, if there is any corrosion or residue on the cable or battery terminal, clean it with a mixture of baking soda and water. Apply this mixture to a clean cloth and gently scrub the affected areas until the corrosion is removed.

Finally, properly dispose of any spilled battery acid and the cleaning solution according to local regulations or guidelines. Reinstall the battery cover if applicable, and you're done! You have successfully disconnected the negative battery cable on your 97 Road King, and can now proceed with the next steps of replacing the fuel lines.

Remove the centre console

To remove the centre console of a 1997 Road King, follow these steps:

Firstly, drain the fuel tank. To do this, you can either siphon the fuel or remove the crossover tube at the front of the tank. If you choose to remove the crossover tube, block off the cross-over lines and leave the fuel in the tank.

Next, disconnect the negative battery cable. Then, remove the console from the canopy. Now, take out the 10 T-20 Torx screws that are securing the canopy to the tank.

Once the screws are removed, slightly raise the canopy and remove the yellow wire from the spade contact on the inboard side.

Inside the tank, you will see the fuel pump isopod sitting on two posts. Lift the fuel pump isopod off the posts. Cut the Otiker clamp from the tubing at the pump outlet and disconnect the tubing. Finally, remove the black and yellow wires from the pump.

Now, you can inspect and replace the pump as necessary. To put everything back together, simply reverse the process.

Remove the tank

To remove the tank from a 1997 Road King, follow these steps:

First, drain the fuel tank. To do this, remove one end of the hose at the front of the tank and plug it. Then, fit a short piece of tubing over the uncovered bung and drain the fuel.

Next, disconnect the power to the fuel pump at the connector in front of the battery and start the bike. When the engine stalls, operate the starter for three seconds to remove the remaining fuel. Now, disconnect the negative battery cable.

Remove the console from the canopy by unscrewing ten T-20 torx screws securing the canopy to the tank. Lift the canopy slightly and remove the yellow wire from the spade contact on the inboard side.

Now, you can begin to remove the tank itself. There are two bolts at the front of the seat that need to be unscrewed. Push the tank forward slightly, then lift it up. Be careful with the breather tubes under the tank, as they are difficult to reconnect.

Cut the fuel lines and remove the pump

To cut the fuel lines and remove the pump from a 1997 Road King, follow these steps:

Firstly, drain the fuel tank. To do this, remove one end of the hose at the front of the tank and plug it. Attach a short piece of tubing to the uncovered bung and drain the tank. Be quick, as the fuel will spray out.

Next, disconnect the power to the fuel pump. Do this by disconnecting the connector at the front of the battery, then starting the bike. When the engine stalls, operate the starter for three seconds to remove the remaining fuel.

Now, disconnect the negative battery cable. Remove the console from the canopy, and then remove the canopy itself by taking out the 10 T-20 torx screws that secure it to the tank.

Once the canopy is removed, lift the yellow wire from the spade contact on the inboard side.

Inside the tank, you will see the fuel pump isopod sitting on two posts. Lift the pump off the posts.

Now you can cut the fuel lines. Squeeze the Otiker clamp at the pump outlet on top and disconnect the tubing. Remove the black and yellow wires from the pump.

At this stage, you can inspect and replace the pump as necessary. To reinstall the new pump, simply follow the above steps in reverse order.

Please note that removing and reinstalling the canopy can be tricky, as you have to deal with the fuel gauge sending unit attached to it.

Frequently asked questions