That's a great tip! removing the tank is a common chore if you are doing much with the wiring of these bikes. It cost a fortune for the Harley dealership to install the bar mounted power port on my bike mostly due to the time required to remove the tank. Similarly the Memphis Shade headlight relocation kit will require the tank to be removed to run wires, although some people manage without doing that.
Easier Fuel Tank Removal
I pulled the fuel tank a few weeks ago to replace the throttle cables, add a tachometer and a 12v charging socket. Let's just call it a learning experience. I became motivated to make it easier to get the crossover tube around the frame. Otherwise, tank removal can't happen.
Use a siphon to remove as much gas as possible. The next thing to do is remove the stock hose. I recommend clamping the crossover hose on both sides of the center that is in front of the frame. Put a catch pan underneath. Cut it! Drain the fuel if there's any left. Get the fuel tank on the work bench. Now, using diagonal cutters or whatever you like, break the stock (single use) hose clamp. Remove the two halves of the hose.
For replacement, I used Gates 5/16" fuel line. It doesn't have to be fuel injection (45 psi) hose. Make two hoses, a little shorter than the stock single hose. Hose clamp the two hoses to the fuel tank. Attach one side of the 90 degree union to one hose with a clamp. Set up the tank on the frame. Attach the other side of the union with a hose clamp. Shorten the hose lines if you feel like it, as not to hit the radiator fan. Finish the setup with the ground wire, the electric connector, and the actual fuel line.
Next time when you need to remove the fuel tank, clamp the two hoses with two hose clamp pliers from the auto parts store. This just might reduce the gas spill potential.
I'll look up the brand of my hose clamps and make it a comment.
![Light Automotive tire Organism Font Space]()
![Motor vehicle Gas Composite material Bicycle part Automotive tire]()
![Blue Light Automotive tire Coil Gas]()
Use a siphon to remove as much gas as possible. The next thing to do is remove the stock hose. I recommend clamping the crossover hose on both sides of the center that is in front of the frame. Put a catch pan underneath. Cut it! Drain the fuel if there's any left. Get the fuel tank on the work bench. Now, using diagonal cutters or whatever you like, break the stock (single use) hose clamp. Remove the two halves of the hose.
For replacement, I used Gates 5/16" fuel line. It doesn't have to be fuel injection (45 psi) hose. Make two hoses, a little shorter than the stock single hose. Hose clamp the two hoses to the fuel tank. Attach one side of the 90 degree union to one hose with a clamp. Set up the tank on the frame. Attach the other side of the union with a hose clamp. Shorten the hose lines if you feel like it, as not to hit the radiator fan. Finish the setup with the ground wire, the electric connector, and the actual fuel line.
Next time when you need to remove the fuel tank, clamp the two hoses with two hose clamp pliers from the auto parts store. This just might reduce the gas spill potential.
I'll look up the brand of my hose clamps and make it a comment.
1 - 18 of 18 Posts
I like these because they don't dig into the hose. Instead of making the threads dig into the hose, the threads are raised. They just grip. The heads are big slots or pick a 6mm (?) socket and turn them.
NORMA 01266704013-000-0538 Hose Clamps, 8 mm-16 mm x 9 mm W4 (Pack of 10): Amazon.com: Tools & Home Improvement
NORMA 01266704013-000-0538 Hose Clamps, 8 mm-16 mm x 9 mm W4 (Pack of 10): Amazon.com: Tools & Home Improvement
www.amazon.com
Thanks for the reply, PugslyCat.
It may be the kind of trick that a shop tech knows how to do and makes extra money by charging the hourly by the 'book'.
The Norma clamps are better than the usual stuff. I don't want to fool around with fuel lines.
I’m also thinking if an no float LSK Fuel Gauge Pro can be installed. The fuel gauge control unit in the diagram below get info from the line connecting both sides. Also do we need the tank removed for working on cables or is it possible just to tilt ( without fuel in it) the tank straight up towards the front( triple tree). Looks like enough of space there..
![Line Font Parallel Slope Diagram]()
1 - 18 of 18 Posts
