Greetings,
Decided to pull my 1995 Road King out of storage after a 4-5 year break from riding. Unfortunately I did not prepare anything to do with the fuel in the tank and a considerable amount of rust has developed. Before cleaning and relining the shop wants everything removed including the fuel level sensor in the left side cap. I have gotten it to this stage, removed the 5 Torx screws but the assembly won't budge. Am I missing something or does it just need a tap here or there to loosen? In addition, it looks as though the black and orange wires will need to be cut and remove connectors to fit through hole for removal. Any help is appreciated.

 

It’s just stuck from sealant or rust or just being a gasket.

once the torx screws are removed then there is nothing holding it. No need to cut any wires. It all removes as a unit.

Just remove slowly so you don’t damage the float mechanism while taking it out. Remember the way it comes out so you can feed back in.

you will need a new gasket, new sealing torx screws as they have a little plastic washer on them.

also suggest using a little fuel resistant gasket dressing on that gasket (non hardening). They can leak when tank is full.

 

Awesome, thanks for the quick reply. May be best to let Dealer remove and reinstall once I get tank done.

 

Spray some penetrating oil in the screw holes and around the plate.
Let soak for a bit . They can be really stuck . The gasket is gonna be junk anyways
Just keep working at it, It'll give it up

WP