Gas tank internals
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Road Master
Joined: Jul 2009
Posts: 900
Likes: 111
From: surrey, england
Gas tank internals
Hopefully getting my tinware back from the painters soon & have just received my 2" gas tank lift from over the pond. So thought i'd sort out the box of bits from when I dismantled the bike ready for painting & came across the gas tank internals, now I remember it was not a straightforward job to remove these, so am hoping it will be a bit easier to put them back in !
Can anyone give me a link that I can download for instructions for fitting these so I make sure I have done it right & also is it advisable to replace the screws and rubber gasket for the top of the tank or can I use the original ones ?
Thanks in advance.
Paul.
Can anyone give me a link that I can download for instructions for fitting these so I make sure I have done it right & also is it advisable to replace the screws and rubber gasket for the top of the tank or can I use the original ones ?
Thanks in advance.
Paul.
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Road Master
Joined: Jul 2009
Posts: 900
Likes: 111
From: surrey, england
here is the write up that was done
https://www.hdforums.com/forum/dyna-...tank-guts.html
https://www.hdforums.com/forum/dyna-...tank-guts.html
Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
Supposedly it is 'cheap insurance' to replace the rubber gasket and screws; but, I just reused mine and 4 years later ... no worries ....
Hope to be working on mine soon, too ....
R/
'Chop
Hope to be working on mine soon, too ....
R/
'Chop
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,897
From: Bedford UK
Hi from a few miles North, in the UK! If you are going to be taking your bike apart a wise investment is a factory service manual and parts book. Between them they are a wonderful cure for sleepless nights and, even better, will help you with just these sort of jobs!
Outstanding HDF Member
Joined: Apr 2006
Posts: 2,555
Likes: 3
From: Clarksburg, PA
That is my write up and I just wanted to say that I re-used the gasket and bolts (with sealant) and no leaks to date.
I had actually taken my tank apart once before when I had some clear coating on the stock tank done, and another time when I swapped to the custom stuff...so they have been re-used twice.
I had actually taken my tank apart once before when I had some clear coating on the stock tank done, and another time when I swapped to the custom stuff...so they have been re-used twice.
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Road Master
Joined: Jul 2009
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From: surrey, england
Have you got alot of snow where you are ? Find it amazing that everything grinds to a halt here with a bit of snow, but then again its not something we are really use too !!!
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Road Master
Joined: Jul 2009
Posts: 900
Likes: 111
From: surrey, england
That is my write up and I just wanted to say that I re-used the gasket and bolts (with sealant) and no leaks to date.
I had actually taken my tank apart once before when I had some clear coating on the stock tank done, and another time when I swapped to the custom stuff...so they have been re-used twice.
I had actually taken my tank apart once before when I had some clear coating on the stock tank done, and another time when I swapped to the custom stuff...so they have been re-used twice.
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Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
Likes: 255
From: From Long Island, now in So. Cal
Watch eBay for the factory service manuals, there's three for your bike (service, electrical, and a parts manual, see third quote below for parts manual)
http://cgi.ebay.com/ebaymotors/Harle...item2a0c4d4a85
Adjusting for Tank Lift:
Fuel Lines:
You can use the first link below like an online parts manual.
http://cgi.ebay.com/ebaymotors/Harle...item2a0c4d4a85
Adjusting for Tank Lift:
You have to open up the tank under the console and remove the sending unit.
I put a half gallon in then I bent the float rod right by the sending unit (the rod has a "V" shape angle there). I opened that angle up a little, reinstalled sending unit and with the bike upright and my weight on it, I recycled the power and run switch and waited for the gauge to settle (theres a delay in the circuit). I had to do this several times to get it right where I wanted it.
Now when the low fuel light comes on I have a half gallon left. Also when my gauge is now reading a half tank and I top it off I usually pump in about 2.2 to 2.3 gallons (4.7 gallon tank)
While your in there you might as well check your internal fuel lines, info here:
https://www.hdforums.com/forum/dyna-...fuel-line.html
I put a half gallon in then I bent the float rod right by the sending unit (the rod has a "V" shape angle there). I opened that angle up a little, reinstalled sending unit and with the bike upright and my weight on it, I recycled the power and run switch and waited for the gauge to settle (theres a delay in the circuit). I had to do this several times to get it right where I wanted it.
Now when the low fuel light comes on I have a half gallon left. Also when my gauge is now reading a half tank and I top it off I usually pump in about 2.2 to 2.3 gallons (4.7 gallon tank)
While your in there you might as well check your internal fuel lines, info here:
https://www.hdforums.com/forum/dyna-...fuel-line.html
Fuel Lines:
Anybody replace there in tank fuel line instead of replacing the whole assembly? I have three locations that have contacted the inside of the tank and have worn down the outside of the tubing, and one has a pin hole.
I think the fix would be to use Gates SAE 30R10 Submersible Fuel Line, using a shorter length so that it doesn't hit the tank walls, and / or putting tie wraps on those contact points. Harley only sells the one line from the tank quick disconnect to the regulator/filter, the other line requires you to buy the fuel pump.
fuel line tank output to pump item #19 P/N 62194-04
Retail: $55.92
Chicago HD: $44.74
Zanotti's: 36.35
fuel pump assembly item # 7 P/N 61016-04B
Retail: $160.00
Chicago HD: $128.00
Zanotti's: 105.92
fuel pump assembly with regulator item #26 75218-04B
Retail: $250.00
Chicago HD: $200.00
Zanotti's: ?
I think the fix would be to use Gates SAE 30R10 Submersible Fuel Line, using a shorter length so that it doesn't hit the tank walls, and / or putting tie wraps on those contact points. Harley only sells the one line from the tank quick disconnect to the regulator/filter, the other line requires you to buy the fuel pump.
fuel line tank output to pump item #19 P/N 62194-04
Retail: $55.92
Chicago HD: $44.74
Zanotti's: 36.35
fuel pump assembly item # 7 P/N 61016-04B
Retail: $160.00
Chicago HD: $128.00
Zanotti's: 105.92
fuel pump assembly with regulator item #26 75218-04B
Retail: $250.00
Chicago HD: $200.00
Zanotti's: ?
Look up part numbers from the first three links below, then order from Zanotti's or Chicago Harley Davidson. (Zanotti's and Chicago Harley Davidson give at least 20% off parts and accessories including aftermarket parts.)
Original Part Numbers (Parts that originally came on your bike):
http://partsfinder.onlinemicrofiche....m_oem/hdmc.asp
Find your year, model, part, then put a 1 in the qty box of the item or items that you want the part number of, then click on "add items to parts list", then click on "send to cart" to get the part number.
Genuine Motor Accessories Part Numbers (chrome, etc.):
http://www.harley-davidson.com/gma/g...bmLocale=en_US
Motor Clothes Merchandise Part Numbers (jackets, boots, etc.):
http://www.harley-davidson.com/mcm/m...bmLocale=en_US
Add /_ _ _ _ for size of an article of clothing after the part number when doing a search on Zanotti's or Chicago Harley Davidson's website's?
small........................./000S
medium..................../000M
large........................./000L
xlarge......................./002L
xxlarge...................../022L
000's are zero's not letters
Zanotti's:
https://shop.zanottimotor.com/catalog/parts
Chicago Harley Davidson:
http://www.chicagoharley.com/shop/advanced_search.php
Original Part Numbers (Parts that originally came on your bike):
http://partsfinder.onlinemicrofiche....m_oem/hdmc.asp
Find your year, model, part, then put a 1 in the qty box of the item or items that you want the part number of, then click on "add items to parts list", then click on "send to cart" to get the part number.
Genuine Motor Accessories Part Numbers (chrome, etc.):
http://www.harley-davidson.com/gma/g...bmLocale=en_US
Motor Clothes Merchandise Part Numbers (jackets, boots, etc.):
http://www.harley-davidson.com/mcm/m...bmLocale=en_US
Add /_ _ _ _ for size of an article of clothing after the part number when doing a search on Zanotti's or Chicago Harley Davidson's website's?
small........................./000S
medium..................../000M
large........................./000L
xlarge......................./002L
xxlarge...................../022L
000's are zero's not letters
Zanotti's:
https://shop.zanottimotor.com/catalog/parts
Chicago Harley Davidson:
http://www.chicagoharley.com/shop/advanced_search.php
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