efi fuel tank removal
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Joined: Nov 2006
Posts: 90
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From: South Wales, UK
hi,
its an 05/06 softail (tc88)
Im doing a bar swap and need to replace the throttle cables, wiring and get acces to the loom for the indicators and the hand control sockets....
thanks
its an 05/06 softail (tc88)
Im doing a bar swap and need to replace the throttle cables, wiring and get acces to the loom for the indicators and the hand control sockets....
thanks
Elite HDF Member
Joined: Feb 2006
Posts: 3,818
Likes: 2
From: Twin Cities
unplug the fuel gauge under tank follow the wires ...2nd disconnect the fuel line its a quick disconnect....... 3rd gas crossover line ......4th take the dash off by undoing the nut and slide torward the bars and dont forget the little vent hose under it in front of tank
Road Captain
Joined: Sep 2007
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Off the top of my head.......remove fuel pump fuse. Crank engine over for a few seconds (this gets rid of the fuel pressure). Disconnect the battery. Remove tank console (acorn nut below speedo). Drain the tank at the crossover line (or just remove crossover line and plug the nipples coming off the tank with some rubber hose with bolts hose clamped at the end). Disconnect the fuel inlet line by pulling down on the metal colar to release the fitting. Unbolt tank (1 bolt at back and one running through the front of the frame). Hopefully I'm not forgetting anything. That's how it works on my 02 fatboy at least. Oh yeah, you gotta unplug the wire disconnect for your fuel gauge. You'll see the fitting right under the tank. There is also a vent line at the front of the tank that pulls off, as well as the fuel pump wires on top of the tank that you'll see once u pull your console offf. It's super easy, specially with a manual to follow.
Last edited by honkylips; Jan 6, 2010 at 03:15 PM.
Intermediate
Joined: Nov 2009
Posts: 43
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From: Galway Ireland
What Dynabob said !There is also a electrical connector under the dash to disconnect.Also a lot Easier if fuel tank empty.I usually take the left hand side of the fuel crossover tube off (remove stock hose clamp and replace with a standard hose clamp, this side not as visable when on side stand)Take your time, careful when loosening nuts/bolts cover tank with towel or something so as not to damage paint.
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Ultimate HDF Member
Joined: Nov 2007
Posts: 6,975
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From: NJ
Pretty good instructions so far. I'll add a couple things.
To remove the fuel supply line from the bottom of the tank pull down on the chrome sleeve of the quick connect.
I cut the clamps on the crossover and replaced them with new hose clamps.
When you disconnect the crossover line gas can and will drain out. To prevent or minimize this the book says to:
a. obtain a short section of hose 5/16 id. Insert a bolt in one end of the hose and install a hose clamp to ensure bolt stays in.
b. Cut clamp from one end of crossover hose. Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gas from the free end of crossover line into a container.
An extra set of hands is very helpful. Next time I do this I'll make sure the tank is almost empty. Just easier and less chance of getting gas all over the place.
Be very careful with the tank. Don't want any scratches in it.
The tank may fit snuggly over the frame so be careful lifting it. May have to work it up and down a bit. Same thing for reinstalling it.
Good luck with your project.
To remove the fuel supply line from the bottom of the tank pull down on the chrome sleeve of the quick connect.
I cut the clamps on the crossover and replaced them with new hose clamps.
When you disconnect the crossover line gas can and will drain out. To prevent or minimize this the book says to:
a. obtain a short section of hose 5/16 id. Insert a bolt in one end of the hose and install a hose clamp to ensure bolt stays in.
b. Cut clamp from one end of crossover hose. Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gas from the free end of crossover line into a container.
An extra set of hands is very helpful. Next time I do this I'll make sure the tank is almost empty. Just easier and less chance of getting gas all over the place.
Be very careful with the tank. Don't want any scratches in it.
The tank may fit snuggly over the frame so be careful lifting it. May have to work it up and down a bit. Same thing for reinstalling it.
Good luck with your project.
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Joined: Nov 2006
Posts: 90
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From: South Wales, UK
thanks very much everyone!!!
the HD workshop manual is about $150 dollars here in the UK - so as you can appreciate Im keen to keep the costs down.
Mr UK taxman took an unexpected chunk of my budget in import duty and VAT on the HCC handlebar set that just arrived, so Im keen to keep costs down.
the HD workshop manual is about $150 dollars here in the UK - so as you can appreciate Im keen to keep the costs down.
Mr UK taxman took an unexpected chunk of my budget in import duty and VAT on the HCC handlebar set that just arrived, so Im keen to keep costs down.
Last edited by ironman; Jan 7, 2010 at 01:19 PM.
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