HELP! Fuel leak
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Novice
Joined: Mar 2010
Posts: 23
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HELP! Fuel leak
I am hoping someone can shine some light on this issue. I have an EFI softail and I had to remove the gas tank. There is a quick release where the fuel line enters the tank. After re-attaching the fuel line to the tank, it now leaks well rather pours once the engine is running and the fuel line is pressurized. I have went to the dealer ship and the o-ring they keep giving me is too big to fit on the male end of the quick connect. Any ideas? Am I just placing the ring in the wrong place?
Road Master
Joined: Jan 2009
Posts: 796
Likes: 0
From: Mission Viejo, CA
I ended up replacing the entire line but, there are those who have used the o-ring from the oil drain plug which is supposed to work. They say to use a mirror and a dental tool to get it out. In any case, you'll probably either have to replace the o-ring or the assy. as the old o-ring is probably torn.
Elite HDF Member
Joined: Apr 2007
Posts: 4,984
Likes: 8
If it is the stock fuel line, you cracked it, replace the fuel line.
If you have replaced it once, keep taking it off and putting it back on.
I have no idea about the o-ring, I have the same one sitting in my parts box.
The original fuel line is plastic, and it cracks really easy. The new one is metal.
I had to replace mine the first time I tried to remove the tank.
A lot of people on the forum have cracked it.
I had my tank off this week. When I hooked the fuel line back up, fuel leaked. I took the line off looked at it a few times and decided the small o-ring inside the tip was bad.
I went to the dealer and got the new o-ring, in the parts book, I have no idea where it goes. It is 20X too big to fit in the tip.
I unhooked the line and hooked it back up several times and it still leaked, just sort of a slow drip.
I had a lot of other things to take care of, before the dealer closed, I left it unhooked for about 30 minutes.
I often take a break from something, if it is pissing me off.
I installed my exhaust, and went back to the fuel line.
Hooked it back up, no leaks. I decided, that sense I had my tank was off for a few days the o-ring dried out. Once it sat with fuel on it for awhile, it sealed again.
I just walked out and checked it, no leaks.
All of this was on an 06, hope it helps.
If you have replaced it once, keep taking it off and putting it back on.
I have no idea about the o-ring, I have the same one sitting in my parts box.
The original fuel line is plastic, and it cracks really easy. The new one is metal.
I had to replace mine the first time I tried to remove the tank.
A lot of people on the forum have cracked it.
I had my tank off this week. When I hooked the fuel line back up, fuel leaked. I took the line off looked at it a few times and decided the small o-ring inside the tip was bad.
I went to the dealer and got the new o-ring, in the parts book, I have no idea where it goes. It is 20X too big to fit in the tip.
I unhooked the line and hooked it back up several times and it still leaked, just sort of a slow drip.
I had a lot of other things to take care of, before the dealer closed, I left it unhooked for about 30 minutes.
I often take a break from something, if it is pissing me off.
I installed my exhaust, and went back to the fuel line.
Hooked it back up, no leaks. I decided, that sense I had my tank was off for a few days the o-ring dried out. Once it sat with fuel on it for awhile, it sealed again.
I just walked out and checked it, no leaks.
All of this was on an 06, hope it helps.
Last edited by tlb; Mar 18, 2011 at 09:38 AM.
Road Master
Joined: Jan 2009
Posts: 796
Likes: 0
From: Mission Viejo, CA
Hmmm... the replacement fuel line that I received was plastic as was the original one.
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Tourer
Joined: Jul 2009
Posts: 325
Likes: 1
From: Northern Ontario, Canada
I had the same problem with mine. Replaced the o-ring and it still leaked. I soon realized that it was leaking where the hose connects to the fitting. Bought a stainless high pressure hose clamp and it works like a charm. I really should replace the assembly, however it has been fine for almost two years and the tank has been off since.
Cheers!
Cheers!
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Elite HDF Member
Joined: Apr 2007
Posts: 4,984
Likes: 8
My original was plastic, the replacement was metal. I actually thought the replacement was plastic until yesterday when I thought it cracked, too. I pulled the line and started looking at it, the end was metal. I actually tapped on it with a screw drive to see if made a metal sound.
Road Master
Joined: Feb 2011
Posts: 1,120
Likes: 4
I think tlb is correct, I took my tank off the winter to do some mods and it broke before I could get it off. My HD parts guy tell me this is the third design on the fuel line to keep it from breaking all the time. Count yourself lucky it's almost $50.00 for an 07 Fatboy.