2009 & Later - Gas Tank Removal - Step by Step - Pics - Harley Davidson Forums



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2009 & Later - Gas Tank Removal - Step by Step - Pics

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Old 09-12-2011, 09:30 PM
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reesestewww reesestewww is offline
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Post 2009 & Later - Gas Tank Removal - Step by Step - Pics

After searching and not finding exactly what I was looking for I posted earlier today asking about removing the gas tank. I needed to run a USB Accessory cable from under the seat to the front of the tank.

Below are my step by step instructions on how I completed this task.

After removing the seat remove this middle bolt with is securing the dash.
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Remove the allen screw on the front side of the dash too.
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Before lifting the dash from the tank unplug this harness from top of the tank.
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Safely place the dash aside. I did not unplug any harness that went from the dash to the ECM.
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Tank at this stage.

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Release this quick disconnect fuel line.
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Unplug this harness from under the tank found on the left side.
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Remove rear tank bolts.
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After removing the rubber caps, remove the front tank bolts.
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Lift the tank and safely set it aside.
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The wire channel is now exposed and I easily ran my wires.
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That's it!
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Old 09-12-2011, 09:38 PM
WEINERDOGBONE WEINERDOGBONE is offline
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Pretty slick. I'll need to know this for winter mods. I take it that you dodn't have to drain the tank like on older models?
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Old 09-12-2011, 09:43 PM
06UltraBig95 06UltraBig95 is offline
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Is there not a cross over line under the tank that needs to be seperated?
But thanx for the write up I will be doing bars very soon, the bike has ABS so I will need to pull the tank as well.
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Old 09-13-2011, 12:59 AM
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Ultra89Rider Ultra89Rider is offline
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When Harley went to the 6 gallon tank, they eliminated the cross over on the front of the tank. On the 5 Gallon models, you still have the cross over tube to deal with when removing the tank on the Pre '08 models.
On the 6 Gallon tanks for Ultra Glide and Ultra Road Glide models, the process is much the same. Just have one more plug for the head set in the dash (if you have the Ultra). There is not any difference in fuel tanks between the ABS equipped bikes and Non-ABS models.
You are not required to drain the tank, but I ran the fuel down so the tank didn't weigh too much.

Last edited by Ultra89Rider; 09-13-2011 at 01:04 AM.
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Old 09-13-2011, 02:26 AM
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Quote:
Originally Posted by reesestewww View Post
After searching and not finding exactly what I was looking for I posted earlier today asking about removing the gas tank. I needed to run a USB Accessory cable from under the seat to the front of the tank.

Below are my step by step instructions on how I completed this task.

....................................

That's it!
I ran a USB cable from my PCV to the front of the tank also. But I did it a little differently, and easier.

I ran my cable under the tank console along with the vent hoses. I stow the end of the cable behind the wire harness at the neck.

You could argue that it's not as clean, but it sure isn't that bad either.
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Old 09-13-2011, 10:05 AM
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Thank You!
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Old 09-13-2011, 10:11 AM
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dnitram dnitram is offline
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Fantastic information! Thanks for taking the time to share!!
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Old 09-13-2011, 10:36 AM
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Redbeard719 Redbeard719 is offline
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Nice write up. Per the service manual, there's one step you missed.

First, pull the fuse for the fuel pump.

Second, start the bike to purge the fuel lines, often at high pressures. This will help to prevent any fuel spray during removal of the fuel lines from the tank.
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Old 09-13-2011, 10:51 AM
jackloganbill jackloganbill is offline
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Thank you, Thank you, Thank you for the post. It takes time to photograph and explain the process and I greatly, greatly appreciate it.

You should get the weekly "Most Helpful Post" award!!!

Jack
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Old 09-13-2011, 10:55 AM
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I told you it was easy. lol
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