Replacing The Fuel Pump In Your 1999 Road King

If you're looking to replace the fuel pump on your 1999 Road King, there are a few steps you'll need to follow. Firstly, drain the fuel tank through the crossover hose at the front of the tank. You'll also need to purge the fuel system by disconnecting the power to the fuel pump and starting the bike. Once the engine stalls, operate the starter for about three seconds to remove any remaining fuel. Next, disconnect the negative battery cable and remove the console from the canopy. Take out the 10 T-20 torx screws securing the canopy to the tank and slightly raise the canopy to remove the yellow wire from the spade contact on the inboard side. Inside the tank, you'll need to lift the fuel pump isopod off the two posts. Cut the Otiker clamp from the tubing at the pump outlet and disconnect the tubing, as well as the black and yellow wires from the pump. Finally, inspect and replace the pump as necessary. The installation of a new pump is done in reverse order.

Drain the fuel tank

To drain the fuel tank of your 1999 Road King, follow these steps:

First, locate the crossover hose at the front of the tank. Remove one end of the hose and plug it. Fit a short piece of tubing over the uncovered bung and drain the tank. Be quick, as the fuel will be flying everywhere.

Next, purge the fuel system. Disconnect the power to the fuel pump at the connector in front of the battery and start the bike. Once the engine stalls, operate the starter for another 3 seconds to remove any remaining fuel.

Now, disconnect the negative battery cable.

Then, remove the console from the canopy.

After that, remove the 10 T-20 torx screws securing the canopy to the tank.

Now, slightly raise the canopy and remove the yellow wire from the spade contact on the inboard side.

At this point, you should be able to see inside the tank. Lift the fuel pump isopod off the 2 posts.

Cut the Otiker clamp (squeeze clamp) from the tubing at the pump outlet on top and disconnect the tubing.

Finally, remove the black and yellow wires from the pump.

Now you can inspect and replace the pump as necessary.

Disconnect power to the fuel pump

Disconnecting the power to the fuel pump is an important step in replacing the fuel pump in your 1999 Road King. Here is a detailed, step-by-step guide to help you through the process:

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To begin, make sure you have the necessary tools and safety equipment, including eye protection and gloves, as you will be working with gasoline. Locate the fuel pump connector in front of the battery. Before disconnecting the power, you will need to drain the fuel tank. To do this, remove one end of the crossover hose at the front of the tank and plug it. Then, fit a short piece of tubing over the uncovered bung and allow the fuel to drain. Be careful, as gasoline will be spraying everywhere.

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Once the tank is drained, it is time to disconnect the power to the fuel pump. Locate the connector in front of the battery and disconnect the power. After that, you can start the bike. This will help purge the fuel system. Once the engine stalls, operate the starter for about three seconds to remove any remaining fuel from the lines. It is important to perform this step to ensure that no fuel is left in the lines, as it can be dangerous when working with electrical components.

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Now that the power is disconnected and the fuel system is purged, you can continue with the fuel pump replacement process. The next step is to disconnect the negative battery cable. This is an important safety precaution to prevent any accidental electrical shorts or arcing while you work on the bike. Make sure to disconnect the negative cable first to avoid any potential sparks near the battery.

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With the power disconnected and the necessary safety precautions taken, you can now proceed with removing the console from the canopy. This will give you access to the fuel pump and other components. Be careful when removing the console, as there may be additional wires or connections that need to be disconnected. Take your time and work methodically to avoid damaging any components.

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After removing the console, you will need to remove the Torx screws securing the canopy to the fuel tank. Count and label the screws to ensure they go back in the correct locations. Once the screws are removed, carefully raise the canopy slightly. You will then need to remove the yellow wire from the spade contact on the inboard side. This will completely disconnect the power to the fuel pump, and you can now proceed with the rest of the fuel pump replacement process, including lifting the fuel pump isopod off the two posts inside the tank.

Remember to work carefully and refer to a repair manual or seek professional assistance if you are unsure about any steps. Working on a fuel system can be dangerous, so take your time and follow the proper procedures to ensure a safe and successful fuel pump replacement.

Disconnect the NEG battery cable

Disconnecting the NEG battery cable is a crucial step when replacing the fuel pump on a 1999 Road King. Here is a detailed guide on how to do it safely and effectively:

First and foremost, safety should be the top priority when working on any electrical system, including your motorcycle's battery. Ensure that the motorcycle is turned off and the engine is not running. Wear protective gear, such as gloves and eye protection, to safeguard against any potential electrical hazards.

Locate the battery: On a motorcycle, the battery can usually be found under the seat or hidden somewhere else on the bike. Refer to your 1999 Road King owner's manual or search online for the specific location.

Identify the cables: The negative cable is typically black and connected to the negative terminal, which is marked with a '-' symbol. The positive cable is usually red and connected to the positive terminal, marked with a '+' symbol. Trace the negative cable to confirm that it leads directly to a bolt on the frame or engine.

Prepare your tools: You will need a suitable wrench or socket to loosen the battery cable connections. It is recommended to have a basic tool kit for motorcycles, which includes various sizes of wrenches and sockets.

Now, let's get started with the disconnection process:

• Disconnect the negative cable: Loosen the nut or bolt securing the negative cable to the battery terminal using the appropriate wrench or socket. Do not allow the wrench to touch any other metal parts of the motorcycle to avoid accidental short circuits. Once loose, carefully remove the cable from the terminal.
• Isolate the negative cable: After removing the cable, ensure that it is isolated and secured away from any metal surfaces to prevent accidental contact and potential sparks. You can use tape or a cable tie to keep the cable away from conductive components.
• Verify the disconnection: Double-check that the negative cable is completely disconnected from the battery terminal. Visually inspect the terminal to ensure that there is no remaining contact between the cable and the battery.
• Prepare for reinstallation: If you plan to reinstall the battery or connect a new one, keep the negative cable safely to the side. Ensure that it is not misplaced or tangled with other components.
• Continue with fuel pump replacement: With the negative cable safely disconnected, you can now proceed with the next steps in the fuel pump replacement process, such as draining the fuel tank and purging the fuel system.

Remember, always work with caution when dealing with electrical systems. By following these steps, you can safely disconnect the NEG battery cable on your 1999 Road King, making it easier to perform maintenance or repairs on your motorcycle's fuel pump.

Remove the console from the canopy

To remove the console from the canopy of your 1999 Road King, you'll need to follow these steps:

First, make sure you have the necessary tools and safety equipment, including gloves and eye protection. Locate the console and identify any screws, bolts, or other fasteners securing it to the canopy. You may need to refer to a repair manual for your specific Road King model to identify these fasteners accurately. Once you've located them, use the appropriate tool to loosen and remove them. Some consoles may also have clips or other types of fasteners, so be sure to check thoroughly.

After removing the fasteners, carefully lift or pry the console away from the canopy. It may be necessary to gently rock the console back and forth to loosen any adhesive or seals. Be careful not to damage the surrounding components or the canopy itself. Once the console is removed, set it aside in a safe place.

If there are any wires or cables connecting the console to other parts of the vehicle, be sure to disconnect them carefully. Label or mark the wires to ensure proper reconnection during reinstallation.

Before proceeding with any further repairs or maintenance, inspect the area for any debris or damage. It is important to ensure that the canopy and surrounding components are in good condition before reinstalling the console or performing other work.

Keep in mind that working on a vehicle can be complex, and it's always recommended to refer to a repair manual specific to your make and model for detailed instructions. Additionally, if you feel uncomfortable performing these tasks, it's best to consult a qualified mechanic or technician.

Lift the fuel pump isopod off the 2 posts

To lift the fuel pump isopod off the 2 posts, you will need to have already drained the fuel tank, purged the fuel system, disconnected the negative battery cable, removed the console from the canopy, and removed the 10 T-20 torx screws securing the canopy to the tank. Once this is done, you can then slightly raise the canopy and remove the yellow wire from the spade contact on the inboard side.

Now, you can lift the fuel pump isopod off the 2 posts. This is done by lifting the pump up, over, and off the 2 posts.

Frequently asked questions