Harley Fuel Pressure Regulator: Replacing The Regulator Like A Pro

Replacing a Harley fuel pressure regulator is a straightforward process that can be done at home with the right tools and parts. The regulator is responsible for maintaining the correct fuel pressure in the engine, and when it fails, it can cause the engine to stall or not start at all. To replace the fuel pressure regulator, the first step is to remove the fuel tank and then the top motor mount. Next, unplug the head temperature sensor and use a Torx bit to remove the sleeve nut at the top of the induction module. The regulator can then be popped out with a twist of a screwdriver, and a new regulator can be installed with some lubricant on the O-rings. Finally, the retainer plate can be pushed into place, and a screwdriver can be used to help seat the regulator.

Removing the fuel pressure regulator

To remove the fuel pressure regulator from a Harley-Davidson motorcycle, you will need to perform the following steps:

Firstly, remove the fuel tank. Next, remove the hemi joint at the top motor mount, and then remove the top motor mount itself (you can leave the horn attached). After this, unplug the head temperature sensor plug. Now, use a Torx bit to remove the sleeve nut at the top of the induction module. At this stage, you should be able to insert a screwdriver between the regulator and the induction module. Twist the screwdriver to pop out the regulator.

You should now have successfully removed the fuel pressure regulator from your Harley-Davidson motorcycle. The next steps would involve preparing and installing the new regulator, which are beyond the scope of this request.

Replacing the fuel pressure regulator

Step 1: Remove the fuel tank and other components

Start by removing the fuel tank and the heim joint at the top motor mount. Then, remove the top motor mount—you can leave the horn attached. Next, unplug the head temperature sensor plug.

Step 2: Remove the old fuel pressure regulator

Using a Torx bit, remove the sleeve nut at the top of the induction module. Insert a screwdriver between the regulator and the induction module, and gently twist to pop out the old regulator.

Step 3: Prepare the new fuel pressure regulator

Lubricate the two O-rings on the new regulator. Install the retainer plate, and push the regulator into place. You can use a screwdriver wedged between the module and the regulator to help seat it as you pull up on the screwdriver.

Step 4: Reassemble and test

Reinstall the fuel tank and any other components that were removed. Start the engine and check for any fuel leaks. Ensure that the fuel pressure is within the specified range for your specific Harley-Davidson model.

Notes and Warnings

It is important to refer to your Harley-Davidson's service manual or seek advice from a qualified mechanic if you are unsure about any steps or procedures. Working on fuel systems can be dangerous, so ensure proper safety precautions are taken to avoid injury or damage.

Ordering a new fuel pressure regulator

When ordering a new fuel pressure regulator for your Harley, it is important to ensure that you are getting the correct part for your specific bike model and year. Fuel pressure regulators are model-specific, so you will need to know the exact make and model of your Harley.

You can find fuel pressure regulators for Harley-Davidson motorcycles at various retailers, including Amazon and eBay. When ordering online, be sure to check the compatibility information provided by the seller to ensure the regulator will fit your bike.

Some factors to consider when ordering a new fuel pressure regulator include the part number, the vehicle's make and model, and the year or range of years the regulator is designed for. For example, the FPF Fuel Pressure Regulator on Amazon is compatible with Harley Davidson models from 2008 to 2017, including the FLHT, FLTR, FLHR, FXS, FXST, FLS, and FLST.

Additionally, you may want to consider the brand and quality of the fuel pressure regulator. It is always a good idea to choose a reputable brand and read reviews from other customers to ensure you are getting a quality product.

When ordering a new fuel pressure regulator, be sure to also order any necessary gaskets, seals, or other components that may be needed for installation. It is also a good idea to check the return policy and warranty information provided by the seller in case you encounter any issues with the part.

Installing a new fuel pressure regulator

Firstly, remove the fuel tank and the heim joint at the top motor mount. It is also necessary to remove the top motor mount, although you can leave the horn attached. Next, unplug the head temperature sensor plug. Use a Torx bit to remove the sleeve nut at the top of the induction module.

Now, insert a screwdriver between the regulator and the induction module, and twist to pop out the old regulator. Lubricate the two O-rings on the new regulator and install the retainer plate. Push the new regulator into place, using a screwdriver wedged between the module and the regulator to help seat it as you pull up on the screwdriver.

This process may vary slightly depending on the model of your Harley-Davidson motorcycle, so it is always a good idea to refer to the specific instructions for your model. Additionally, ensure that you are taking the necessary safety precautions when performing any maintenance on your vehicle.

Symptoms of a faulty fuel pressure regulator

A faulty fuel pressure regulator can cause a host of issues with your Harley. Here are some key symptoms to watch out for:

• Engine Performance Problems: A bad regulator can cause a loss of fuel pressure, leading to hard-starting, rough running, stalling, and a lack of power. The engine may struggle to start and run smoothly due to insufficient fuel pressure.
• Check Engine Light: Your Harley's engine computer monitors for issues that impact emissions. A faulty fuel pressure regulator can trigger the check engine light and store diagnostic trouble codes.
• Black Smoke from the Tailpipe: A faulty regulator can cause the engine to run rich, resulting in excessive fuel consumption and black smoke from the tailpipe.
• Fuel in the Regulator's Vacuum Line: If the diaphragm inside the regulator ruptures, fuel may be drawn into the vacuum line and enter the intake manifold, affecting engine performance.
• Vehicle Cranks but Doesn't Start: A faulty regulator can prevent the engine from receiving adequate fuel pressure, resulting in a cranking but non-starting condition.

If you notice any of these symptoms, it's advisable to inspect and potentially replace the fuel pressure regulator to restore your Harley's performance and reliability.

Frequently asked questions