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How to Change a Super Glide Gas Tank

Changing the fuel tank on a recent Dyna Super Glide is much more difficult now that it was as recently as 2005. Since 2006, all Harley Dyna Models have been equipped with the closed loop, Delphi electronic fuel injection. This electronic black box system often confuses the diagnosis of engine problems and complicates what were once routine maintenance and repair chores. The good news is that you will not need a laptop to remove and replace your gas tank. The bad news is that the job is now considerably less intuitive than it used to be.

Instructions

Remove the Old Tank

1

Pull the electrical caddy cover off -- on the right side of the bike near the battery compartment -- with your hands. Put the blades of two, small flat-head screwdrivers on either side of the fuel pump fuse and pry out the fuse.

2

Shift the bike into neutral, start the engine and wait for the engine to die. Try to start the bike for another five seconds.

3

Remove the seat fender tab screw and washer with an Allen wrench. Pull the seat back and up to expose the battery. Disconnect the cable from the negative battery post with an open end wrench.

4

Reach under the tank and pull up on the fuel tank fitting and simultaneously pull down on the fuel line.

5

Unscrew the acorn nut in the middle of the instrument panel with an Allen wrench. Pull the panel up and pull apart the plug and socket ends of the fuel pump module connector.

6

Plug one end of a short section of 5/16-inch diameter hose with a 5/16-inch diameter bolt. Constrict a worm-style hose clamp around the bolt by turning the adjusting screw with a screwdriver.

7

Position a large gas can next to the left side of the motorcycle near the fuel tank. Cut off one of the two clamps from the ends of the crossover hose with tin snips.

8

Hold the open end of the short section of 5/16 hose next the crossover hose fitting that you just unclamped. In as close to one motion as possible, replace the unclamped end of the crossover hose with the short section of 5/16-inch hose and insert the free end of the crossover hose into the fill hole of the pre-positioned gas can.

9

Drain the gasoline into the gas can. Clean up any spillage with rags and immediately carry the rags to a well-ventilated location.

10

Loosen the remaining hose clamp on the crossover line and the clamp on the continuous vent line with a screwdriver. Pull both lines off their fittings.

11

Loosen and remove both the front and rear mounting bolts, washers and nuts under the tank with an open end wrench. Pull the male and female halves of the fuel gauge connector apart.

12

Remove the tank by lifting straight up. Carry the tank to a well-ventilated location and allow the tank to air out.

13

Remove the 10 top plate screws from the top plate of the old tank with a Torx socket and socket wrench. Remove the top plate and top plate gasket. Discard the gasket and the screws.

14

Reach into the tank and push down on the fuel pump to remove it from the fuel pump housing so it will fit through the hole. Remove the complete fuel pump assembly including the fuel pump, fuel pump housing, fuel filter screen, hose, fuel level sender and float from the old fuel tank.

Install the New Tank

15

Loosely attach the new fuel tank to the mounting brackets with the front and rear tank mounting bolts, washers and nuts using an open-end wrench. Install the old crossover line and vent line to the new tank using new hose clamps and a screwdriver. Tighten the front and rear mounting bolts with an open-end wrench.

16

Install the old fuel pump hose and a new fuel line hose clamp on the fuel filter fitting. Install the complete old fuel pump assembly in the new tank until the rubber spacer on the bottom of the assembly rests on the bottom of the new fuel tank.

17

Reconnect the fuel line. Reconnect the fuel pump module connector.

18

Replace the instrument panel and tighten the acorn nut with an Allen wrench.

19

Re-install the fuel pump fuse in the electrical caddy. Replace the electrical caddy cover.

20

Reconnect the loose cable to the negative battery post with an open-end wrench. Replace the seat. Refasten the seat mounting tab to the rear fender with an Allen wrench.

21

Refuel the motorcycle.