gas tank removal

B

beautiful disaster

New member
Looking to remove my gas tank on my 09 RK for a paint job. Just ordered the service manual but it won't be in for 7 to 10 days. Anyone know the deal on the tank removal along with the gas gauge. Thanks for any replys.
 
The gas gauge needs to be disconnected below the tank and then the pins need to be removed from the socket, noting their relative positions. Then gently pull up on the gauge and it pulls right out. There is a fuel line quick disconnect on the left rear lower corner of the tank. This is a dry break connector and if you gently pull down on the chrome piece while supporting the actual connector, it will come off with virtually no loss of fuel. Next you need to remove the instrument console. There should be one bolt or screw just in front of the seat and then a dome nut just below the speedo. Remove these and gently raise the console sufficiently to disconnect the various plugs, connectors and lines under there. There are two bolts at the front of the tank, one either side, that fasten the forward legs of the tank to the frame. Remove these bolts and you should be able to lift off the tank. I don't think you have a fuel crossover line at the front of the tank, but if you do, you'll need to cut the clamp on one side and drain the fuel. This is messy and you'll need some hose as well as a container for fuel. Hope this helps and I ask any posters who think I made any mistakes to correct me.
 
Short of running the bike out of fuel prior to doing the work, I wish there were a cleaner way of removing the fuel crossover line.
 
http://cgi.ebay.com/ebaymotors/HARLEY-TANK-5-16-FUEL-LINE-CROSSOVER-QUICK-DISCONNECT-_W0QQcmdZViewItemQQhashZitem1c07d865eeQQitemZ120390706670QQptZMotorcyclesQ5fPartsQ5fAccessories
 
Herko sells a quick-release hose connector on Ebay for $50 shipped. For that money and considering how little I remove the tank I will probably just use my hose-clamping pliers and resign myself to spilling some gas.
 
The OP was asking for info regarding removing the gas tank on his '09 bike. There isn't a cross over line on the '09s. For the pre '09 bikes that do have a cross over the addition of a chrome quick disconnect (Herko, Colder, etc) is a great upgrade. Many members have posted they only intended to remove their tank once and didn't think the $50.00 investment was warranted. Who can plan that far ahead? If you decide to remove your tank more than once it's a great investment. Just my .02.
 
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