Fuel Line
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Tourer
Joined: Sep 2007
Posts: 296
Likes: 1
From: South Carolina
Fuel Line
So, I just had a repeat problem with my 2004 fuel-injected Ultra. \\; Curious if anyone else has had this issue. \\; With around 11,000 miles on the bike, it started running bad while on ride back from Sturgis to Maryland. \\; Would stop for gas and run great for about 70 miles, then it'd start missing and carrying on. \\; Gas up again... good to go for another 70 miles. \\; Turns out it was the internal fuel line from the pressure regulator to the quick disconnect on the tank. \\; Apparently, it rubs on the tunnel inside the tank and wears through. \\; Well, now with 56,000 miles on the bike, it did it again... would run great for about 110 miles then start acting up. \\; Sight unseen, bought a new line and fuel filter... replaced it last night and sure enough... there were 2 holes worn through.
My local dealer says they've never heard of it before. \\; Of course, the first dealership was in Ohio and the guy just happened to know because he'd fixed the same thing a week before my visit. \\; Fortunately, he also had an extra line in stock. \\; If the bike is missing, back firing, detontates, stalls at lights... doesn't run smooth... but, then is better (but not necessarily perfect) with a full tank of gas you might want to consider this as a possible issue. \\; Any one else seen this happen?
My local dealer says they've never heard of it before. \\; Of course, the first dealership was in Ohio and the guy just happened to know because he'd fixed the same thing a week before my visit. \\; Fortunately, he also had an extra line in stock. \\; If the bike is missing, back firing, detontates, stalls at lights... doesn't run smooth... but, then is better (but not necessarily perfect) with a full tank of gas you might want to consider this as a possible issue. \\; Any one else seen this happen?
Road Master
Joined: Feb 2007
Posts: 1,248
Likes: 25
From: York, PA
RE: Fuel Line
Had the same issue with my 04 Roadglide, climbing a hill on rt 40 outside of Fredneck MD and the bike just died. Towed in, internal fuel line was the issue. Never had another problem after that.
Stage II
Joined: Jun 2008
Posts: 2
Likes: 0
RE: Fuel Line
I just had that same problem on my '02 Road Glide. I had ridden from Phx to R.I. The day before I got to R.I. the bike started misfiring &\\; running rough when it got low on fuel. The problem did go away when I filled up. I got to R.I. on a Friday &\\; had scheduled an appointment (for the next day, \\;Saturday) \\;3 weeks earlier to take it to a local dealer for maintenance after riding that far &\\; knowing I had to ride all the way back. When I fired it up that morning it wouldn't idle. I had to crack the throttle to keep it running whenever I came to a stop. The dealer changed the plugs, etc. but couldn't find the problem right away. It took them 5 days to find that the same hose you are talking about had gone bad. I was told by the dealer that the hose goes porous after a while &\\; develops pinholes &\\; it's \\;a common problem (I think that if it was that common, they would have found it sooner). They \\;replaced the hose &\\; I rode all the way back to Phx without a problem (6.5K miles total). The Road Glide had about 26K miles on it when this happened. I got the bike in '05 with about 9400 miles on it. After what the dealer said I just made a note to change it out @ about 20-25K miles just to not be caught off guard.
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Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
RE: Fuel Line
Is the hose P/N 62228-03?
I just got off the phone with my local HD parts guy and he \\;\\\\\\;said the hose should be inspected when doing the filter.
Going to order one along \\;with a filter kit.
I just got off the phone with my local HD parts guy and he \\;\\\\\\;said the hose should be inspected when doing the filter.
Going to order one along \\;with a filter kit.
Thread Starter
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Tourer
Joined: Sep 2007
Posts: 296
Likes: 1
From: South Carolina
RE: Fuel Line
Think replacement with filter is smart... annoying though. \\; We're talking $3 piece of plastic... ends up costing over $100 for all parts!
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Seasoned HDF Member
Joined: Jun 2006
Posts: 28,473
Likes: 3,950
From: Vermont
RE: Fuel Line
Common problem that the hoses get pin holes in them. \\; One problem was the length of the hose, since been upgraded and corrected.
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Outstanding HDF Member
Joined: Jan 2006
Posts: 3,015
Likes: 5
From: Alaska
RE: Fuel Line
Any dealer that says they never heard of it must have their head up their butt so it muffles the sound. 
It has happened to at least 6 people I ride with and it is mainly due to the line rubbing against the tunnel in the fuel tank. Not hard to replace, just time consuming.
It has happened to at least 6 people I ride with and it is mainly due to the line rubbing against the tunnel in the fuel tank. Not hard to replace, just time consuming.
