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  #1  
Old 18th March 2012
Screw Loose Dan's Avatar
Screw Loose Dan Screw Loose Dan is offline
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Default Removing EFI fuel tank (How-To Video)

There was a thread a short while ago asking about removing the tank off an EFI bike. It's one of those things that once you do, you won't look at the directions the second time. But, for someone that has never done it, it can be intimidating I suppose. So, I made a video to show how quick and easy removing the tank is. There's really no reason not to remove the tank if it makes what you are doing easier.

A couple things to consider:
  • I am demonstrating this on a 2007 1200R. I think it's the same basic procedure for all EFI bikes. I think the 2010+ bikes might have a bit different electrical connection and fuse panel. The bikes with single seats will obviously be a bit different in removing the seat.
  • The manual says to empty the tank first. I've never emptied the tank. Who is right? I personally think it's more unsafe to figure out how to siphon off the gas then just leave it in there. Even a full 3.3 gallon tank is only going to weigh ~25 lbs. A half full tank much lighter, but you do need to be careful with fuel sloshing around. Chose your own poison.
  • While I show "purging" the fuel system by running it dry, I almost never actually do it. I figured it's best to show the "more right" way.
  • I'm not saying my way is the right way and it's certainly not the only way. Do what works for you.
If you hurt your bike or yourself following my demonstration...only blame yourself for following a guy folks call Screw Loose.

Removing the tank:
2007 Sportster Fuel Tank Removal - YouTube
2007 Sportster Fuel Tank Removal


Installing the tank:
2007 Sportster Fuel Tank - YouTube
2007 Sportster Fuel Tank


FSM lists the following torque specs:
Quote:
Fuel tank mounting screw 15-20 ft-lbs 20.4-27.1 Nm
IMPORTANT!! - The Factory Service Manual is very clear about this! Gasoline can kill you. It is dangerous and explosive. After reading the manual, I'm pretty sure most people that do this will die. Please read your FSM for further important information.

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2007 - 883L/90" -current project - (Black bike)

Last edited by Screw Loose Dan; 1st August 2018 at 00:48..
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  #2  
Old 18th March 2012
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Thanks for the great videos! I will have to do this procedure at some point, now I know exactly how to do it.
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  #3  
Old 18th March 2012
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Wow, I never thought of using the battery cover for a tool tray.
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  #4  
Old 18th March 2012
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Nice tutorial dan..
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  #5  
Old 18th March 2012
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Thanks guys. I know it's not the most riveting thing to watch, but if it helps a couple people I guess it's good enough.

Quote:
Originally Posted by motorend View Post
Wow, I never thought of using the battery cover for a tool tray.
It's portable and always with you when working on the bike.

It makes a very handy tool and small parts tray. I probably use it a little too much and have several times had it overflowing with stuff.
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  #6  
Old 19th March 2012
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Funny....I have this written up myself as I did it for another XLF member a while back....but the video was much better than what I did. Great job again Dan.

The only difference I had was disconnecting the negative battery terminal. I know 99.9999% of the time that pulling the maxifuse will be all you need but pulling the maxifuse doesn't disrupt power to the entire bike....only removing the negative battery cable does. The bike's starter still has power going to it directly from the battery and is grounded. This is one reason that during most installation instructions for parts they tell you to remove the negative battery cable from the ground stud.
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  #7  
Old 19th March 2012
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Yeah, I agree pulling the negative battery cable would be the safest. But, not even the manual suggests it. And, 99% of the time I'm too lazy to pull the Maxi-fuse or even purge the fuel line. (Amazing I've lived this long.) But, I do understand the risk and wouldn't discourage someone from doing it if it made them feel better.

Do you recommend emptying the tank? Curious how many people do that. And I wonder how they manage to do it safely with things commonly found around the house/garage.
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  #8  
Old 19th March 2012
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Quote:
Originally Posted by Screw Loose Dan View Post
Do you recommend emptying the tank? Curious how many people do that. And I wonder how they manage to do it safely with things commonly found around the house/garage.
I've had my tank of a few times and have NEVER emptied it. But I did heed the warnings of others about it shifting and I was careful. No issues to date...
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Old 19th March 2012
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Quote:
Originally Posted by Brad View Post
I've had my tank of a few times and have NEVER emptied it. But I did heed the warnings of others about it shifting and I was careful. No issues to date...
Yeah, I've never emptied mine, except when I swapped tanks. But, I'm sure that wasn't the safest thing I've ever done either.

It's never seemed bad to me, but it is worth being careful (dropping a tank would suck). Of course, I have the 3.3 tank, perhaps with the goliath 4.5 tank (or whatever they are) it might be more of a problem.
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Old 19th March 2012
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Nearly 30 years of messing with bikes .. I've never emptied a tank to take it off ... nor taken the battery out (unless it needed to come out for a reason)

HD litigation paranoia.. or maybe their bike are more prone to blow up ?

Just use some common sense - sure some folks still have it out there - n if they dont then they maybe shouldnt be messing with it in the 1st place

That said ..... GREAT VIDEO !!
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