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03 heritage classic carbureted, have had the repair shop change ignition coil, turn signal security module, ignition switch ,circuit breaker, fuel petcock. Finally after been towed 4 times, they are telling me that the liner inside the gas tank is slowly peeling off and that the particles with the gravity settles around the inside gas filter on the petcock. This is why i can go 150 miles or 10 miles & it shuts off. Anybody out there had the same issues.
You should be able to see liner if it is coming apart just looking in your tank. Run it out of gas or drain it. I have yet to see a stock Harley tank do this.
There was rust inside of the gas tank of a totaled Honda GoldWing that I rebuilt on to a salvaged frame. When I got it on the road, the engine ran okay but got weak and eventually stalled. When my roadside trouble shooting revealed that the fuel filter was full of rust, I back-flushed it and rode home. I bought a six pack of small transparent fuel filters and installed one in the fuel line between the gas tank and the fuel pump. As soon as one filter filled up with rust, I replaced it with a fresh filter. IIRC, I used three of those filters until the rust was flushed from the gas tank.
Maybe you should run the tank almost dry and clean the petcock screen a few times. When the inside of the tank is clean, top-off the gas on your way home from a ride so the bike is parked with a full tank and there's no chance for the inside of the gas tank to rust or corrode.
FWIW, my cousin now owns an '82 Low-Rider (that my b-i-l purchased new) and for a while, after a long, freeway speed ride, it would also quit running, but after sitting for several minutes it would start up and run normal for a while.
It took a while but he finally figured out that the bike was running out of fuel and eventually tracked the problem to the fuel line "nipple" on the RH fuel (mini-bob) tank not being large enough to allow enough fuel to flow through the "cross-over" line to the LH tank and petcock.
He reamed the "nipple" out with a flexible drill bit and the bike runs great to this day.
2002 Road King FLHRCI had similar issue with the grey stuff peeling inside the tank. took it to a place that deals with this sort of issue in Ocala Florida. They completely stripped and relined the inside of the tank and destroyed the outer paint in the process. Cost me a new paint job but tank has been fine for 50,000 miles now.
I've heard of people draining the tank then filling it half full of BBs or small screws and shaking the **** out of it. Supposedly removes the remaining liner and any rust that might have formed inside the tank. Then you buy the tank liner stuff and line the inside the tank again. Sounds simple enough but I never did it so I have no first hand knowledge.
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