Replacing The Fuel Pump In A 2001 Road King

If you're looking to replace the fuel pump in your 2001 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 3 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 raise it slightly to remove the yellow wire from the inboard side. You can then lift the fuel pump isopod off the 2 posts inside the tank. Cut the Otiker clamp from the tubing at the pump outlet and disconnect the black and yellow wires from the pump. Finally, install the new pump in reverse order.

Drain the fuel tank

To drain the fuel tank of a 2001 Road King, follow these steps:

First, remove the seat of the motorcycle. Then, remove the negative cable from the battery by unthreading the bolt and taking off the acorn nut and Phillips screw (with a flat washer) from the instrument console. Place a clean shop towel on the forward part of the rear fender and carefully lift the instrument console from the fuel tank, placing it upside down on the towel.

Next, bend back the flexible metal clip to free the harness conduit from the bottom of the console. Remove the Speedometer Connector from the back of the speedometer by depressing the external latches and using a rocking motion to separate the pin and socket halves. Gently pry the three latches upward to release the lock ring from the back of the speedometer.

Now, turn the console over and remove the speedometer from the top side. Take off the gasket from the console speedometer bore. With the fuel tank exposed, 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 gas will be flying everywhere.

Disconnect power to the fuel pump

Disconnecting the power to the fuel pump is a crucial step in replacing the fuel pump in your 2001 Road King. Here is a detailed, step-by-step guide to help you through the process:

Step 1: Drain the Fuel Tank

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

Step 2: Purge the Fuel System

• Disconnect the power to the fuel pump at the connector located in front of the battery.
• Start the bike, and once the engine stalls, operate the starter for about 3 seconds to remove any remaining fuel.

Step 3: Disconnect the Battery

Disconnect the negative battery cable. Ensure you have unthreaded the bolt and removed the negative cable from the negative (-) terminal.

Step 4: Remove the Console

Remove the console from the canopy. This step can be tricky, as you will need to deal with the fuel gauge sending unit attached to the canopy.

Step 5: Remove the Canopy

• Remove the 10 T-20 torx screws that secure the canopy to the tank.
• Slightly raise the canopy and remove the yellow wire from the spade contact on the inboard side.

Step 6: Access the Fuel Pump

Inside the tank, lift the fuel pump isopod off the two posts.

By following these steps, you will have successfully disconnected the power to the fuel pump and can proceed with the next steps to replace the fuel pump in your 2001 Road King.

Disconnect the NEG battery cable

Disconnecting the negative battery cable is an important first step when working on your 2001 Road King's fuel pump. Here's a detailed guide on how to do it safely and effectively:

• Locate the Battery: Before you begin, put on safety gear, including gloves and eye protection. The battery on a motorcycle is typically located under the seat or in another hidden spot. Refer to your 2001 Road King's manual or search online to pinpoint its exact location.
• Prepare the Work Area: Ensure you have adequate lighting and space to work comfortably. Place a clean cloth or towel nearby to wipe your hands and catch any spills.
• Disconnect the Negative Cable: Once you've located the battery, identify the negative cable. It's usually black and marked with a "-" symbol or a black "-" symbol on the terminal clamp. Use the appropriate tool, such as an adjustable wrench or socket, to loosen the clamp screw that secures the cable to the battery terminal. Do not let the wrench touch any other part of the bike to avoid accidental short circuits. Once loose, carefully remove the cable from the terminal.
• Secure the Cable: After disconnecting the negative cable, secure it away from the battery to prevent accidental contact. You can use a cable tie or wrap it with electrical tape to ensure it doesn't touch any metal surfaces.
• Verify Battery Condition: With the negative cable disconnected, take a moment to inspect the battery. Look for any signs of damage, leaks, or corrosion. If there is corrosion around the terminals, carefully clean it using a wire brush or a mixture of baking soda and water.
• Note Cable Routing: Before proceeding further, take note of how the negative cable is routed. It should be clear of any moving parts and not touching any sharp edges that could damage the insulation. This step will help you ensure proper installation when it's time to reconnect the cable.
• Work Safely: Keep in mind that fuel and batteries can be a dangerous combination. Ensure there are no open flames or sparks nearby, and if possible, cover the battery terminals with tape or insulated caps to prevent accidental contact.

Remember to follow safety protocols and refer to your motorcycle's manual or a trusted mechanic if you have any doubts. Working on your Road King's fuel pump involves handling flammable liquids and electricity, so take your time and work methodically to ensure a safe and successful outcome.

Remove the console from the canopy

To remove the console from the canopy of your 2001 Road King, follow these steps:

Firstly, remove the seat and disconnect the negative battery cable by unthreading the bolt and removing the black negative cable from the battery's negative terminal. Next, remove the acorn nut and Phillips screw (with its flat washer) from the instrument console. Place a clean shop towel on the forward part of the rear fender and carefully lift the instrument console from the fuel tank, placing it upside down on the towel.

Now, you need to bend back the flexible metal clip to free the harness conduit from the bottom of the console. This will allow you to remove the Speedometer Connector from the back of the speedometer. Depress the external latches and use a gentle rocking motion to separate the pin and socket halves.

Once that's done, gently pry the three latches upward to release the lock ring from the back of the speedometer. Turn the console over and remove the speedometer from the top side. Finally, remove the gasket from the console speedometer bore.

This process will allow you to successfully remove the console from the canopy of your 2001 Road King.

Remove the canopy

To remove the canopy of your 2001 Road King, you'll need to first drain the fuel tank through the crossover hose at the front of the tank. Remove one end of the hose, plug it, and fit a short piece of tubing over the uncovered bung to drain the gas.

Next, you'll need to 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 about 3 seconds to remove any remaining fuel.

Now, disconnect the negative battery cable and remove the console from the canopy. You can then remove the 10 T-20 torx screws securing the canopy to the tank.

At this point, you should be able to carefully raise the canopy. Remove the yellow wire from the spade contact on the inboard side.

Once the canopy is removed, you can proceed with replacing the fuel pump.

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