Mercedes Mullins
Pin holes in a motorcycle's fuel line can be caused by a number of issues. One user on a Harley Davidson forum suggested that the problem could be down to the bike having sat idle in a garage for a few years. Another user suggested that the problem could be down to the fuel line itself, which has been a source of problems for years with no improvement from the manufacturer. A fuel pressure test can be carried out to identify the problem.
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What You'll Learn
Fuel line problems in Harley Davidson motorcycles
Pin holes in the fuel line of a motorcycle can be caused by a number of issues. One way to test for a pin hole in the fuel line is to turn the key on, which pressurises the fuel line, and then unplug the pump fuse, which makes the pump inoperable. If the fuel line has a hole, it will leak fuel after 10 seconds or more and the bike won't start. This is known as the 'back yard test'.
Harley-Davidson motorcycles are no exception to fuel line problems. Owners of Harley-Davidson motorcycles may encounter issues with their fuel pumps, which are an essential component that feeds fuel from the tank to the engine. Recognising the signs of a failing fuel pump can save riders from potential breakdowns and costly repairs. Symptoms of fuel pump failure include a lack of smooth acceleration, sputtering, and trouble starting the engine. A failing pump might not be able to maintain the necessary fuel pressure, leading to engine stalls, particularly at higher temperatures.
Harley-Davidson recommends regular maintenance and replacing the fuel filter per the service interval to prevent many common fuel pump issues. While some motorcyclists enjoy tackling repairs themselves, fuel system problems might require professional expertise due to the pump’s critical role in the motorcycle’s performance and safety.
In addition to fuel pump issues, Harley-Davidson has also issued a recall for certain 2022 and 2024 motorcycle models due to a potential issue where the front brake lines may contact the fuel tank, leading to possible damage. This defect could result in a brake fluid leak and loss of front brake function, which increases the risk of a crash.
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The back yard test
To perform the back yard test, follow these steps:
- Turn the key on to pressurise the fuel line.
- Unplug the pump fuse to make the pump inoperable.
- Wait for 10 seconds or more.
- If the engine starts and runs for 2 seconds or more, it's holding pressure and not leaking enough to cause problems.
- If the engine doesn't start, it's likely that there is a hole in the fuel line.
It's important to note that the back yard test is not a substitute for a proper fuel pressure test, which can reveal problems in the fuel line prior to any repairs being made. However, it can be a useful first step to take before getting the wrenches out.
In addition to the back yard test, there are other methods to check for a pin hole in the fuel line. One user on the Harley Davidson Forums reported that they found the issue by simply removing the fuel cap with the vehicle running and observing a fine mist splashing up out of the fuel filler hole. Another user suggested reseating every connector, fuse, relay, and sensor to try and fix the problem.
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Fuel pump tests
There are a few ways to test for a pin hole in your fuel line. One user on a Harley Davidson forum recommends the following:
> By turning the key on, you pressurize the fuel line. By unplugging the pump fuse, the pump becomes inoperable, i.e. if the pump is engaged, even a fuel line with a hole, the bike will start. Since the fuel line is pressurised, a fuel line with a hole will leak fuel after 10 seconds or more and the bike won't start.
Another user recommends a similar test, but suggests waiting 15 seconds before starting the bike. They also suggest that the bike will start and run for a few seconds if there is no hole in the fuel line.
A third user suggests a fuel pressure test to reveal a problem in the line.
Another user suggests that the fuel line could be the source of the problem, and that it could be rubbing and causing an air leak. They suggest that the area that rubs could be sleeved or covered in shrink fit tubing to fix the issue.
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Internal gas line leakage
Pin holes in a motorcycle's fuel line can be caused by internal gas line leakage. This can be identified by turning the key on, which pressurises the fuel line. If the pump fuse is then unplugged, the pump becomes inoperable. If the pump is engaged, even a fuel line with a hole will start the bike. However, because the fuel line is pressurised, a fuel line with a hole will leak fuel after 10 seconds or more and the bike won't start.
There are a few ways to test for pin holes in a fuel line. One user on a Harley Davidson forum recommends the 'back yard test' described above. Another user suggests a fuel pump test: turn on the ignition, wait a few seconds, pull the fuel pump fuse, and wait at least 15 seconds. If the bike starts and runs for a few seconds, there is likely a problem with the fuel line. A third user suggests a fuel pressure test, which will reveal a problem in the line.
Pin holes in fuel lines are a common problem with Harley Davidson motorcycles. One user on a forum complains that the fuel line has been a source of problems for years with no improvement from the manufacturer. They recommend that anyone doing their own replacement should find a way to sleeve the area that it rubs, which will fix the problem once and for all. They suggest using shrink fit tubing, which will add tons of life or last until there's a reason to go into the tank, like a filter change.
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Fuel line replacement
Pin holes in a motorcycle's fuel line can be caused by a variety of factors, including age, inactivity, and general wear and tear. If you are experiencing this issue, it is important to address it promptly as fuel leaks can be dangerous.
To replace the fuel line, you will need to purchase a replacement fuel line that is compatible with your specific motorcycle model. You can typically find this information in your motorcycle's service manual or by consulting a mechanic or dealer.
- Locate the fuel line: The fuel line is typically located near the fuel tank and engine, and it may be necessary to remove certain components to access it. Refer to your motorcycle's service manual or seek guidance from a mechanic if you are unsure.
- Disconnect the fuel line: Before disconnecting the fuel line, ensure the engine is cool and relieve any pressure in the fuel system. This can be done by turning the key to the "on" position and then removing the pump fuse, as described in the "backyard test" mentioned in some forums.
- Remove the old fuel line: Carefully remove the old fuel line, taking note of its routing and any clamps or fittings that need to be transferred to the new fuel line.
- Install the new fuel line: Install the new fuel line, ensuring it is securely clamped or fitted in place. Follow the routing of the old fuel line and refer to the service manual for any specific instructions or torque specifications.
- Test the new fuel line: Once the new fuel line is installed, test for any leaks by pressurizing the fuel system and inspecting for fuel spray or mist. You can do this by turning the key to the "on" position and observing the fuel filler hole, as described in some forum posts. If no leaks are detected, start the engine and observe for any unusual behaviour.
It is important to note that working on fuel systems can be dangerous, and it is always recommended to consult a qualified mechanic or technician if you are unsure about any aspect of the replacement process. Additionally, ensure you are working in a well-ventilated area and take appropriate safety precautions when handling fuel.
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Frequently asked questions
You can test for a pinhole in your motorcycle's fuel line by turning the key on, unplugging the pump fuse and waiting for 10 seconds. If the engine starts after 10 seconds or more and runs for 2 seconds, it's holding pressure and not leaking enough to cause problems.
A pinhole in a motorcycle's fuel line can sound like an air leak.
You can fix a pinhole in your motorcycle's fuel line by finding a way to sleeve the area that it rubs. Even something as simple as shrink fit tubing will add tons of life or have it last until there's a reason to go into the tank like the filter change.
