Well done Rudy, glad you fixed it. I had not considered the heat drying them out. so learned somthing today.. ride safe buddy and keep your boots in the breeze... Del.
Hi mate, thanks for your comment, believe it or not, that is the standard seat from the XL883L as it came from the factory, it is quite hard, but if you'd like one at least with that you can just order it up from the parts desk ! ... The bike is Penny's bike, she chose the colours herself and are the original 58 Duo Glide colours ... thanks for watching, Cheers Del
When I need help with my Harley, I can go to my shop manual or Delboy's garage for a more clear explanation. You never let me down. Thanks, Scott. Cincinnati, Ohio
Gee thanks Scott, you are too kind, im glad the videos casn help you...and thanks also for taking the time to get in touch. ride safe my friend.. all the best. Del.
I can't show you it as I don't intend to do it, but it's very simple, as is ignition key re-location, coil re-location 7 tank lift kits, just buy the kit online and it comes with easy step by step instructions, thanks for watching, Del
Delboy you're spot on 'auld son...had to drop the stock peanut and threw an Iron 883 tank on my 2010 '48...the peace of mind is simply...night and day. Plus no more jibs in from the lads with the fat tanks. Great vids as usual. Cheers.
Hi mate, like i said a few times, post up something really simple and basic, a suddenly half a dozen guys have been wondering that answer for ages....makes me glad i do them, because if i felt they weren't useful to people id stop bothering tomorrow and just build silly bikes.. thanks again Del.
Thanks Delboy - my boyfriend was freaking out worried gas would be every were your quick pic on removal of tank saved him from sleeping in the garage. Happy Holidays Alan and Diana Croydon, Pa USA
Hi Diana, Thats great news you are able to deal with it safely now, you're not alone and its a very common worry when removing the tank, but as you can see, the factory make it real easy and safe to remove by yourself.. Have a wonderful Christmas and a safe and happy new year... all the best, Del & Penny.
An oldie video but a damn goodie! Thanks for a very comprehensive tutorial. Now it makes me curious as to how to replace or otherwise service the gas tank filter. Thanks again for what you do my friend.
Thank you so much for the help!! With the help of your videos I was able to change out all my cable, and adjust them too! I was able to instal ape bars and not pay the 600 dollars the harley dealership wanted. Now i'm removing my tank for a paint job, and you are helping me do this too! Thank you so much for the videos! From Venice California, thank you!
+Romano Simeon Hi Romano, how nice to hear from you all the way from Switzerland - glad you enjoy the videos and that they can help you out - thanks for watching, ride safe, Del
Thanks guys, exactly what I needed to see for when I change my handlebars to re route things. So much better than trying to decipher a manual. Subscribed.. (Nice colour paintwork too.!)
Thanks for the endorsement buddy, im glad the pads finally bedded in and found their mojo, the thing to note here, is that already you are more knowledgeable and equipped to keep your bike safe, imagine a guy asking YOU now why his back chomper is squealing like a pig, and is it dangerous....you can tell him with experience and pass on the torch of knowledge and guidance, and that's right what the biker brotherhood is all about... well done mate, and thanks for taking the time to watch.. Del.
hi Malcolm, all i can say with the rocker gaskets is its real simple and take your time...the only tricky bit is getting the bugger out and back in as there is no clearance under the frame...i use a damp chamois leather draped over it to stop it getting scratched as you wriggle and drag it out....other then that, just be careful and take your time.. good luck, Del.
So much easier than I expected. I am going to go pull my tank off now so I can get at the spark plugs. Thanks for this video, it just made things that much easier!
MF41, wow, thank's for sharing, mate. Have to replace an ignition switch and couldn't get the tank off --- and you appeared like a guardian angel showing the way. Give your mum a big hug because she raised you well.... JCG, Tampa, Fl., USA
Hi Julianne. Thanks so much for those very kind words..im glad the video could help you out, and happy you could use it.. Hope the weather is still warm and dry in Fl. all the best, take care.. Del.
Hi Throck,Harley introduced the peanut tank in 1957...because they only introduced the Sportster itself in 1957. And yes, your'e right, most 48 owners do seem to get just under 50miles from brim to reserve, I can't believe that is just coincidence LOL! Further to that, if you Stage 1 tune & fit pipes to your bike you will see a slight drop in MPG,so then you will have to fill it right up to get your 48miles, but hey ho, it's not a tourer, thanks for watching, take care Del
Thank you sir, I am very impressed with how simple the removal was. I have some material interduced into my tank and need to remove and flush out. Thank you again
$600? That's extortiante! (but doesn't surprise me)... it bares out the statistic that Harley dealers make 75% of their income from non-chassis sales and service! Selling bikes alone isn't profitable! Glad the videos have helped you and it's amazing to have been able to reach out to a fellow rider all the way over in California - thanks for taking the trouble for letting us know, it makes it all worthwhile! Ride safe and good luck with your custom job! Del & Penny
Nice one Del. Things were simpler with carbs! In response to the chap who asked about Bandit fuel filter fitting, I did one on a Mk1 earlier this year for a mate. I got a motorcycle filter (i.e. not one for a car as they are too big!) from Vehicle wiring products. It was a 6mm unit. Just remember it has an orientation for fuel flow (there is an arrow in flow direction). TBC
Hi mate....you can lift the front using a tank lift kit.. its a simple bracket that locates the front mount higher...they come in 1, 2 or 3inch lifts....just search them on the net and you'll find plenty of choice... and they come with detailed instructions too... hope that helps.. Del.
Painters tape (triple layer) doesn't slime your paintwork like duct tape, that being the point. Good video! Since many tank pulls will be to replace fuel pumps on bikes that sat unused for a long time, note the internal fuel hoses should always be replaced as age and disconnection then reconnection to replacement fuel pumps are famous for causing (exasperating) leaks.
Hi buddy, it will be pretty much the same, i believe there is a link pipe at the front under the head stock to disconnect, and possibly a few other changes to the sportster setup....but in principle taking a fuel tank off is the same, disconnect the fuel, any sender connections and then the mounting bolts....sorry not to be more help, just take your time and be vigilant, it shouldn't be too hard. good luck, Del.
Awesome. Thanks for this. Need to run some wires under the tank for a new Legend air suspension. Can't take the Los Angeles freeway potholes any longer with the stock 1" suspension.
Great video. Nice part about pulling harness not wires(some don't know 101). I've got the gold 50th on my tank but really like that "pog" emblem on that bike.
You're welcome, mate, we just post up the jobs we do, and if it helps anyone then that's great... thanks for taking the time to comment and watching, it's much appreciated, Cheers Del
Thank you very much, excellent instructions. You were right, I was scared to take my tank out (I need to do some wiring), after watching this - not any more ;) Cheers!
Moonfleet41 Thanks Del. In fact I do say "how hard can it be" and when I get started it turns into a half day work. Most of the time because I don't have the right tools (or too big) or I can't reach the bolts. What a nightmare to install forward controls without removing the exhaust (just 4 bolts) or swapping the handlebar by yourself (all greased-up and trying to hold everything together). BTW, I want to replace the spark plug wires with pretty (Yellow Screaming Eagle) ones. Is there a heat shield on the long one (back cylinder). I could not see under the tank and don't want to run into surprises. Cheers, Alex
Alex Poduţ I never found a heat shield on mine mate, and HT leads can tape a hugh amount of heat, in fact, even if the rest on the head they wont melt....
Thanks for the helpful tips. I'm about to undertake replacing the stock speedometer with the new 4" combo speed/tach kit and fuel level sensor kit on my 09 Sportster XL1200L. I'll let you know how it goes.
Thanks for showing us that-- not useful to me, but very interesting. I really like that fuel line, double-ball-bearing valve. Very clever-- with an electrical lock-out to boot!
Damn man,props to poor Penny.You had her working her ass off on this video.Hanging upside down,bending every which way,holding the camera and a flashlight at the same time, while she was probably twisted up like a pretzel.And to top it off you might have given her a heart attack when you scratched or almost scratched her beautiful fender.Hope you at least cooked or took her to dinner.Great job Penny.Oh,and you too Del. LOL LOL LOL Only 48 miles to a tank ??!!?? What the....
Hi Rudy,I have to say I am in the dark on this one,as never had this happen.Using common sense,replace both Orings top& bottom if you can,and check the ball valves are closing properly & there is no grit or dirt preventing the ball seating properly..also push the balls in & out with your finger to make sure the springs are working properly & clean the entire joint to make sure nothing is getting in the way..it's a case of elimination & tracing the fault..sorry I can't be more help, good luck,Del
You hit a diamond right there...I think the bikes you refer to are the "Zero Choppers" stylee, and "Rough Crafts enigineering" too, but they are both custom companies, and i was refering to the main factories Honda Suzuki et al...also the japanese themselves have some amazing ingenuity when it comes to building a bobber around an old Knuckle motor...something i think they Americans find a bit sacrilegious... dont you just love the bike world for its diversity?..lol. take care buddy, Del.
Not quite sure I understand your question, but I think you mean the ball valve fuel hose connector.. when you remove this with the spring back collar there is a very tiny amount of fuel that escapes, and again when re-fitting, is this what you mean? Or is it leaking continuously? Could it be you've not re-fitted correctly?
You can fit one you know, they are not hard to adapt, but you'll need to fit a fuel pump too (and the FI tank) in order to overcome the spring pressure as your carb bike just uses gravity....personally i like the carb setup...nice and simple, thanks for watching chum.. Del.
Thank You so much for your video. I just picked up a 2011 883L that has a dent in the tank where the bike hit something and I want to replace it with a OEM tank that matches but I didn't have a clue how to go about it. Now I am sure I can do the job myself.
Moonfleet41 Wow I am just now getting around to it but I really wanted to thank you again for your video. Almost 9 months ago I changed out the tank with my wife lending a helping hand and the job went smooth and easy because I watched your video a dozen times before I picked up a tool. THANKS!
Steve Taylor Hope it didn't take you 9 months to do the job there Steve lol lol (only joking mate!).. glad to hear it went well... plenty more Harley vids if you need them buddy... thanks for taking the time to let us know!
Hi. Yet again another great video (albeit an oldie). Many thanks for another super clear and concise explanation of how-to remove the tank. Just a couple quick questions: For an '09 1200 sportster (essentially identical to the '08 48 model you use in the video), would you recommend emptying the tank or at least using most of the fuel before removal? And, to replace upper rocker box gaskets, would you recommend simply lifting the rear of the tank a bit instead of actually removing it? - which I've seen some do. (P.S. What a beautiful tank, both shape and colour). (PPS Would you happen to remember if you've done a video on replacing rocker box gaskets on a Sportster?)
Always drain a tank before you remove it, it just makes it easier to handle... and yes you can remove rocker covers by just lifting the tank, it jams on the frame slightly at the rear so it's abit of a jiggle, and I've done many videos replacing gaskets on big twins and it's pretty much the same thing! Good luck with it.
Hi, there, thats a common mystery, clever Harley like to hide things in plain view just to make them really hard to find...lol .the turn signal bodies are designed to swivel and move in case they get just such an impact and then they move rather than snap off..Stand in front of the bike, look at the master cylinder fluid window, and right next to it is the mirror shaft...between the two you will see a tiny hole..down inside is a little grub screw (alun key)..tighten that up and you're good to go
Great video. All I want to do is thread the wiring harness from a gear indicator (that I have attached to the handlebar) back to the data link connector. Looks like there is a sheath under the tank that protects the wiring harness from the heat of the engine. I'm guessing I don't have to remove the tank, maybe just remove the back bolt to tip it up a little? Is there enough give on the fuel collar, you think? Then just push the wiring thru from the front?
On the FI bikes just pull back the spring collar and release the fuel hose (it will leak hardly any residue as there is a spring loaded ball valve), and lift the tank from the front, not the back, if you lift from the back you will hit the tank against the top yoke and damage it... so slide the bolt out that goes across the headstock, lift the tank up about 8" and prop it up with a block... but it's just as easy once you've disconnected the fuel line to take out the back bolt and just remove the tank...!
Great video Delboy, much appreciated, gives me a little insight on what I need to do. Is this method the same for softtail models do you know? I need to have mine painted due to an unfortunate incident with a ladder.
Thanks for the video - it's made things more clear for me as I prepare to change the rear rocker cover gaskets on my XL1200L - any tips on that much appreciated! Made myself a wooden stand as per your video - just need to persuade my missus to come and help like your does!
Moonfleet41 thanks for sharing the info regarding the tank removal can you please show us how to remover rear fender/mudguard? as will be sending mine away for respray tank and both mudguards. I ride a 1200 XL Sportster 56 model thanks in advance for your help
Just wanted to drop a line & let you know I enjoyed your videos. Need some help! I lifted the tank on my 2008 Nightster by 2" & I now have a gas leak. Any recommendations?
Hi Paul, no, your bike will have a much simpler connection, usually a hose that can be pulled off once the clip is loosened off... Cant exactly remember what it looks like, its been a long time since i took the tank off a carbed Harley... buty it'll be reasonably obvious when you look at it..!! hope that helps mate..!
Thinking about it, the wires fit directly into the pump unit and fuel sender 'through the base plate'...the two units are sealed to the base plate, and perhaps there is no live feed open to the fuel...id hope not anyway, i like my left leg in the place it was intended..lol..
Cheers mate, excellent post Del Boy, clear as a bell !! Sorted ! Love the colour of your bike by the way..I have a 2008 Roadster that has the ECM under the seat in the rear fender as well - quick question for ye, what type of mono seat is that? a HD product? Keep it safe, F
Hi Stu. Sadly the old Mk1 banger i have doesn't have fuel filter, and i cant remember what they look like, ive had a couple of Mk2's over the years, but never had cause to change one so id be on the dark till i looked at it.. they cant be that hard though mate, usually inline between the tap and the carbs, so easy enough to slip the hose off each end of the filter, and insert a new one... if you get stuck send me a closeup photo so i can see what it looks like, hope that helps, Del
cont..Use a length of correct diameter fuel hose (6mm) fuel pipe clips on all joints (so 4 off). Do not make the pipe too long or you’ll get air locks. Remove the tank and fuel/vacuum pipes. Cut the fuel pipe (I like a new pipe as the old one can be a loose fit over the spigots) fit the filter with clips then offer the over length pipe into position checking there is sufficient space for the unit and cut surplus off the pipe at either end (I like to see the filter…) TBC
Excellent video. I need to do this tomorrow to get a the wiring loom under the tank. I want to fit a tracker on a permanent live and wire up my Garmin Zumo on a switched live, so following a zoom is important. On my 883 there is a cover in front of the fuse box and in there are two connectors. One goes to a sensor below the tank. My connector is disconnected a wire shorts the two pint in the other part of the connector attached to the loom. It hast a stage 1 fitted. Do you know why this sensor has been purposely disconnected?
So many variations on this mate, depending on year and specification, the way Harley design things is to have one overall wiring harness for all Sportsters and then connect up what they need and blank off what they don't, so depends on your bike, model and year, and no, I wouldn't keep that information to hand, even a Harley Master Tech would have to look that up and they'd probably have to see it first too... however, if you invest in a Genuine H-D manual, then it'll all be in there my friend, a worthy purchase... good luck with it, hope it goes well for you.
Hey Delboy, I recently bought an 08 Nightster 1200. The previous owner put a 48 tank on it. Will the low fuel light still come on at the appropriate time? Being new to harley I was worried that it being a smaller tank the system would still think it has the bigger tank on it and somehow that would screw things up. Thanks for the help and videos!
Hi mate...your Harley tank has a plate under the left side and attached to that is the fuel pump and a big filter....they stick up into the tank and are designed to be submerged in the fuel.....so the fuel pump, (which looks a bit like a toilet roll tube) measures the level of the fuel as is drops down the side of it's body......so it doesn't matter weather the pump is sitting in your 48 tank, or a 50 gallon truck tank.....once the fuel level gets to 4 liters left, its activates the light.... Best advice if you are ever worried is to carry a fuel flask with a spare litre in it, and when the light next comes on.....zero the trip meter, and ride deliberately to run the tank dry till the bike stops....then you will for ever know exactly how many miles you have in reserve...and the spare litre will get you to a garage.. hope that helps mate... cheers, Del.
I know, WTF are they playing at designing a tank that has such silly range, but hey ho, its the most popular sportster of all time, so its hardly an own goal aye.... thanks for taking pity on our Penny, shes a good old stick, will happily skulk about in a damp cold garage with me for hours, and make tea in between shoots too aye...what a star she is.. i think ill keep her on aye..?.. cheers buddy, Del.
That was so simple... my Sportster must be about the same. The last bike I had the tank off was a 1970 CB 350 that had an bridging tube and always seemed to make a mess when draining the tank. Leads to my next question. The plate needs to be pulled off to replace the fuel filter? How often should that really be done? Now, I do have a problem I woke up to. 2007 HD Sportster C, 1200 CC... I was going to ride my bike to work. But the security system activated. I tried my other key/ fob set & it still would not start... put it on a trickle charger & took the car to work. . . still will not start. Checked the fob battery 3.1 volts - ok, looked at the fuses - pulled the main first, like in your changing the battery video :-) & I did find some oxidation, so I wire brushed them & put electrical grease on them - like I user on the light bulbs. Still will not start. I looked at the Delphi connector & the ECU connector & both are clean, & now restated... still will not start. Any thoughts on this? Thank you for your videos, liked the one on ID & emergency information. NickNarcowich@Yahoo.com Sacramento, California, U.S. of A.
If this started with your security system kicking off, Nicholas, then it's probably routed in your alarm fobs... they must be replaced with the genuine H-D batteries and not the cheap kind you get from the drug store... often with many cases of this, people grab the spare fob and expect it to work, without considering that it's obviously the same age as the other one... replace them both and charge the battery and it should work fine! I've had this issue twice myself and it cured it both times - the cheap batteries are a liability, I found on the genuine H-D ones work !
cont connect pipe to carbs then fit clip at CV carbs. Refit the tank, reconnect the fuel and vacuum pipes (plus clips) start the engine and watch the clean fuel flow…
ordered the o rings on line was hard to find but after changing both it worked turns out I left the bike off to long and here in texas heat got to the rings and dried them out o rings fit and back working again
Ive seen many pics of 883s with a relocated speedo to the left on the suspension bar i think it was, i really like the look it gives the bike with a straight dragbar but im very lost in how to do it, if you could give me a couple of tips or show me the procedurei would be really thankful
Delboy, thanks so much to you and your wife fro taking the time to do these vids.
They're all absolutely brilliantly explained!
Thanks buddy, you're most welcome... we have great fun making them and it's a bonus that it helps a few people too! Ride Safe!
Well done Rudy, glad you fixed it. I had not considered the heat drying them out. so learned somthing today.. ride safe buddy and keep your boots in the breeze... Del.
Hi mate, thanks for your comment, believe it or not, that is the standard seat from the XL883L as it came from the factory, it is quite hard, but if you'd like one at least with that you can just order it up from the parts desk ! ... The bike is Penny's bike, she chose the colours herself and are the original 58 Duo Glide colours ... thanks for watching, Cheers Del
When I need help with my Harley, I can go to my shop manual or Delboy's garage for a more clear explanation. You never let me down. Thanks, Scott. Cincinnati, Ohio
Gee thanks Scott, you are too kind, im glad the videos casn help you...and thanks also for taking the time to get in touch. ride safe my friend.. all the best. Del.
I can't show you it as I don't intend to do it, but it's very simple, as is ignition key re-location, coil re-location 7 tank lift kits, just buy the kit online and it comes with easy step by step instructions, thanks for watching, Del
Thanks for taking the time to do these videos. They are a great help to us newbies.
Delboy you're spot on 'auld son...had to drop the stock peanut and threw an Iron 883 tank on my 2010 '48...the peace of mind is simply...night and day. Plus no more jibs in from the lads with the fat tanks. Great vids as usual. Cheers.
Thanks mate, the peanut tank does look the biz, but stopping every 15mins for fuel is not the biz lol ... !
Hi mate, like i said a few times, post up something really simple and basic, a suddenly half a dozen guys have been wondering that answer for ages....makes me glad i do them, because if i felt they weren't useful to people id stop bothering tomorrow and just build silly bikes.. thanks again Del.
I think if i repeated what she said off camera, you would think she is not so sweet....oops..! thanks for watching buddy, cheers, Del.
Thanks Delboy - my boyfriend was freaking out worried gas would be every were your quick pic on removal of tank saved him from sleeping in the garage. Happy Holidays Alan and Diana Croydon, Pa USA
Hi Diana, Thats great news you are able to deal with it safely now, you're not alone and its a very common worry when removing the tank, but as you can see, the factory make it real easy and safe to remove by yourself.. Have a wonderful Christmas and a safe and happy new year... all the best, Del & Penny.
An oldie video but a damn goodie! Thanks for a very comprehensive tutorial. Now it makes me curious as to how to replace or otherwise service the gas tank filter.
Thanks again for what you do my friend.
Thank you so much for the help!! With the help of your videos I was able to change out all my cable, and adjust them too! I was able to instal ape bars and not pay the 600 dollars the harley dealership wanted. Now i'm removing my tank for a paint job, and you are helping me do this too! Thank you so much for the videos!
From Venice California, thank you!
Excellent video on taking the tank off. Wanted to do some graphics on my tank.Love your illustrations,directions and the close ups. Cheers gunner
Hi Delboy - You do really a great job. All your videos are very clear and 100% helpful. Thank you very much - from Switzerland!
+Romano Simeon Hi Romano, how nice to hear from you all the way from Switzerland - glad you enjoy the videos and that they can help you out - thanks for watching, ride safe, Del
Thanks guys, exactly what I needed to see for when I change my handlebars to re route things.
So much better than trying to decipher a manual.
Subscribed..
(Nice colour paintwork too.!)
Thanks for the endorsement buddy, im glad the pads finally bedded in and found their mojo, the thing to note here, is that already you are more knowledgeable and equipped to keep your bike safe, imagine a guy asking YOU now why his back chomper is squealing like a pig, and is it dangerous....you can tell him with experience and pass on the torch of knowledge and guidance, and that's right what the biker brotherhood is all about... well done mate, and thanks for taking the time to watch.. Del.
hi Malcolm, all i can say with the rocker gaskets is its real simple and take your time...the only tricky bit is getting the bugger out and back in as there is no clearance under the frame...i use a damp chamois leather draped over it to stop it getting scratched as you wriggle and drag it out....other then that, just be careful and take your time.. good luck, Del.
So much easier than I expected. I am going to go pull my tank off now so I can get at the spark plugs. Thanks for this video, it just made things that much easier!
MF41, wow, thank's for sharing, mate. Have to replace an ignition switch and couldn't get the tank off --- and you appeared like a guardian angel showing the way. Give your mum a big hug because she raised you well.... JCG, Tampa, Fl., USA
Hi Julianne. Thanks so much for those very kind words..im glad the video could help you out, and happy you could use it.. Hope the weather is still warm and dry in Fl. all the best, take care.. Del.
Hi Throck,Harley introduced the peanut tank in 1957...because they only introduced the Sportster itself in 1957. And yes, your'e right, most 48 owners do seem to get just under 50miles from brim to reserve, I can't believe that is just coincidence LOL! Further to that, if you Stage 1 tune & fit pipes to your bike you will see a slight drop in MPG,so then you will have to fill it right up to get your 48miles, but hey ho, it's not a tourer, thanks for watching, take care Del
Thank you sir, I am very impressed with how simple the removal was. I have some material interduced into my tank and need to remove and flush out. Thank you again
You're welcome buddy, glad it could help you out !
$600? That's extortiante! (but doesn't surprise me)... it bares out the statistic that Harley dealers make 75% of their income from non-chassis sales and service! Selling bikes alone isn't profitable! Glad the videos have helped you and it's amazing to have been able to reach out to a fellow rider all the way over in California - thanks for taking the trouble for letting us know, it makes it all worthwhile! Ride safe and good luck with your custom job! Del & Penny
Nice one Del. Things were simpler with carbs! In response to the chap who asked about Bandit fuel filter fitting, I did one on a Mk1 earlier this year for a mate. I got a motorcycle filter (i.e. not one for a car as they are too big!) from Vehicle wiring products. It was a 6mm unit. Just remember it has an orientation for fuel flow (there is an arrow in flow direction). TBC
Hi mate....you can lift the front using a tank lift kit.. its a simple bracket that locates the front mount higher...they come in 1, 2 or 3inch lifts....just search them on the net and you'll find plenty of choice... and they come with detailed instructions too... hope that helps.. Del.
Honestly, the paint on your tank and fenders are soooo smoooth!
And great video... ;)
I can't thank you enough for all the help you've given me to fix my Harley. Thank you.
Thanks Ivan, you are most welcome.. im glad the videos can help you. Del.
Ivan The Terribrew
Thanks Del...I needed this info for the rocker cover gasket job
Painters tape (triple layer) doesn't slime your paintwork like duct tape, that being the point. Good video!
Since many tank pulls will be to replace fuel pumps on bikes that sat unused for a long time, note the internal fuel hoses should always be replaced as age and disconnection then reconnection to replacement fuel pumps are famous for causing (exasperating) leaks.
Hi buddy, it will be pretty much the same, i believe there is a link pipe at the front under the head stock to disconnect, and possibly a few other changes to the sportster setup....but in principle taking a fuel tank off is the same, disconnect the fuel, any sender connections and then the mounting bolts....sorry not to be more help, just take your time and be vigilant, it shouldn't be too hard. good luck, Del.
Just what I was looking for. Great explanation with instructions. Thanks!!
Thanks Johnny, glad it helped you buddy... ride safe mate.
Awesome. Thanks for this. Need to run some wires under the tank for a new Legend air suspension. Can't take the Los Angeles freeway potholes any longer with the stock 1" suspension.
Well done Ted, thats a great little How-To with lots of detail....just how it should be... thanks for posting that mate, cheers, Del;.
Excellent, to answer your question, the reason why I need to take my tank off is to change the rocker covers - cheers Del.
Great video. Nice part about pulling harness not wires(some don't know 101). I've got the gold 50th on my tank but really like that "pog" emblem on that bike.
Thanks buddy, the emblem was a copy of the '58 Duo Glide, all those great things are now re-available from your dealer for retro fit on modern bikes!
Simples! Brilliantly clear and straight forward. Awesome work!
Another great tutorial Delboy. Many thanks.
You're welcome, mate, we just post up the jobs we do, and if it helps anyone then that's great... thanks for taking the time to comment and watching, it's much appreciated, Cheers Del
Love this guys videos. Very helpful information
Thanks Josh, glad it helped you. Del
Thank you very much, excellent instructions. You were right, I was scared to take my tank out (I need to do some wiring), after watching this - not any more ;)
Cheers!
Well done Alex, always just ask yourself 'how hard can it be?'... it's just nuts and bolts mate, good luck with it, all the best, Del
Moonfleet41
Thanks Del. In fact I do say "how hard can it be" and when I get started it turns into a half day work. Most of the time because I don't have the right tools (or too big) or I can't reach the bolts. What a nightmare to install forward controls without removing the exhaust (just 4 bolts) or swapping the handlebar by yourself (all greased-up and trying to hold everything together).
BTW, I want to replace the spark plug wires with pretty (Yellow Screaming Eagle) ones. Is there a heat shield on the long one (back cylinder). I could not see under the tank and don't want to run into surprises.
Cheers,
Alex
Alex Poduţ
I never found a heat shield on mine mate, and HT leads can tape a hugh amount of heat, in fact, even if the rest on the head they wont melt....
Thanks for the helpful tips. I'm about to undertake replacing the stock speedometer with the new 4" combo speed/tach kit and fuel level sensor kit on my 09 Sportster XL1200L. I'll let you know how it goes.
Thanks once again
Your videos are really the best available
Thanks for showing us that-- not useful to me, but very interesting. I really like that fuel line, double-ball-bearing valve. Very clever-- with an electrical lock-out to boot!
Thats great news Ryan, and exactly why we load them up, im glad it helped you buddy, good luick Del.
Great video. Needed to prep my bike for a move and this did the trick.
Thanks DelBoy, I followed your instructions and had no problem
Well done Paul, pretty easy once you know the three things to disconnect... glad it worked for you... ride safe, Del.
Your video is so helpful. Thank you so much!
Thanks a ton. Big help on my '07 Sportster
Damn man,props to poor Penny.You had her working her ass off on this video.Hanging upside down,bending every which way,holding the camera and a flashlight at the same time, while she was probably twisted up like a pretzel.And to top it off you might have given her a heart attack when you scratched or almost scratched her beautiful fender.Hope you at least cooked or took her to dinner.Great job Penny.Oh,and you too Del. LOL LOL LOL Only 48 miles to a tank ??!!?? What the....
Hi Rudy,I have to say I am in the dark on this one,as never had this happen.Using common sense,replace both Orings top& bottom if you can,and check the ball valves are closing properly & there is no grit or dirt preventing the ball seating properly..also push the balls in & out with your finger to make sure the springs are working properly & clean the entire joint to make sure nothing is getting in the way..it's a case of elimination & tracing the fault..sorry I can't be more help, good luck,Del
You hit a diamond right there...I think the bikes you refer to are the "Zero Choppers" stylee, and "Rough Crafts enigineering" too, but they are both custom companies, and i was refering to the main factories Honda Suzuki et al...also the japanese themselves have some amazing ingenuity when it comes to building a bobber around an old Knuckle motor...something i think they Americans find a bit sacrilegious... dont you just love the bike world for its diversity?..lol. take care buddy, Del.
Not quite sure I understand your question, but I think you mean the ball valve fuel hose connector.. when you remove this with the spring back collar there is a very tiny amount of fuel that escapes, and again when re-fitting, is this what you mean? Or is it leaking continuously? Could it be you've not re-fitted correctly?
You can fit one you know, they are not hard to adapt, but you'll need to fit a fuel pump too (and the FI tank) in order to overcome the spring pressure as your carb bike just uses gravity....personally i like the carb setup...nice and simple, thanks for watching chum.. Del.
Very helpful. Thanks for posting.
Thank You so much for your video. I just picked up a 2011 883L that has a dent in the tank where the bike hit something and I want to replace it with a OEM tank that matches but I didn't have a clue how to go about it. Now I am sure I can do the job myself.
Thats great news Steve... we love to hear that the videos have been of use... good luck with it and all the best.. Del.
Moonfleet41 Wow I am just now getting around to it but I really wanted to thank you again for your video. Almost 9 months ago I changed out the tank with my wife lending a helping hand and the job went smooth and easy because I watched your video a dozen times before I picked up a tool. THANKS!
Steve Taylor Hope it didn't take you 9 months to do the job there Steve lol lol (only joking mate!).. glad to hear it went well... plenty more Harley vids if you need them buddy... thanks for taking the time to let us know!
Moonfleet41 LOL No changing the tank took about thirty minutes or so but I have been busy with other things and riding my bike every chance I get.
Hi. Yet again another great video (albeit an oldie). Many thanks for another super clear and concise explanation of how-to remove the tank. Just a couple quick questions: For an '09 1200 sportster (essentially identical to the '08 48 model you use in the video), would you recommend emptying the tank or at least using most of the fuel before removal? And, to replace upper rocker box gaskets, would you recommend simply lifting the rear of the tank a bit instead of actually removing it? - which I've seen some do. (P.S. What a beautiful tank, both shape and colour). (PPS Would you happen to remember if you've done a video on replacing rocker box gaskets on a Sportster?)
Always drain a tank before you remove it, it just makes it easier to handle... and yes you can remove rocker covers by just lifting the tank, it jams on the frame slightly at the rear so it's abit of a jiggle, and I've done many videos replacing gaskets on big twins and it's pretty much the same thing! Good luck with it.
Delboy I love you, thank you very much, from Chile !!!
Thank you Lucas... you're very kind!
Thanks mate, glad it helped you out... ride safe, Del
Hi, there, thats a common mystery, clever Harley like to hide things in plain view just to make them really hard to find...lol .the turn signal bodies are designed to swivel and move in case they get just such an impact and then they move rather than snap off..Stand in front of the bike, look at the master cylinder fluid window, and right next to it is the mirror shaft...between the two you will see a tiny hole..down inside is a little grub screw (alun key)..tighten that up and you're good to go
No, the motor was that colour from the factory..its actually a matt grey powdercoat..that way they dont tarnish, and the water just runs off...
Thank you for saving me SO MUCH money!!!
Great video. All I want to do is thread the wiring harness from a gear indicator (that I have attached to the handlebar) back to the data link connector. Looks like there is a sheath under the tank that protects the wiring harness from the heat of the engine. I'm guessing I don't have to remove the tank, maybe just remove the back bolt to tip it up a little? Is there enough give on the fuel collar, you think? Then just push the wiring thru from the front?
On the FI bikes just pull back the spring collar and release the fuel hose (it will leak hardly any residue as there is a spring loaded ball valve), and lift the tank from the front, not the back, if you lift from the back you will hit the tank against the top yoke and damage it... so slide the bolt out that goes across the headstock, lift the tank up about 8" and prop it up with a block... but it's just as easy once you've disconnected the fuel line to take out the back bolt and just remove the tank...!
Great video Delboy, much appreciated, gives me a little insight on what I need to do. Is this method the same for softtail models do you know? I need to have mine painted due to an unfortunate incident with a ladder.
I like that ball valve - I find it to be quite brilliant and I wish my '05 Sportster had one (carbureted) to make tank removal easier.
Cheers Tim.
Thanks for posting!
Thanks for the video - it's made things more clear for me as I prepare to change the rear rocker cover gaskets on my XL1200L - any tips on that much appreciated! Made myself a wooden stand as per your video - just need to persuade my missus to come and help like your does!
Like the number plate mount, where can i buy this please? great vid mate, answerd a lot of questions, nice n clear :)
Very good bro!!! Super ease!
Thanks bro really helped me with my wire tuck lot easier with out tank
Glad it helped Kali !
Good video, it helped me out right away. Thanks.
Moonfleet41 thanks for sharing the info regarding the tank removal can you please show us how to remover rear fender/mudguard?
as will be sending mine away for respray tank and both mudguards.
I ride a 1200 XL Sportster 56 model
thanks in advance for your help
Just wanted to drop a line & let you know I enjoyed your videos. Need some help! I lifted the tank on my 2008 Nightster by 2" & I now have a gas leak. Any recommendations?
Great video. Exactly what I was looking for :)
Ty for your excellent video
That was a great video. My Sportster is a carb model. Will it have that same self sealing valve on the supply line or is that just on the EFI models?
Hi Paul, no, your bike will have a much simpler connection, usually a hose that can be pulled off once the clip is loosened off... Cant exactly remember what it looks like, its been a long time since i took the tank off a carbed Harley... buty it'll be reasonably obvious when you look at it..!! hope that helps mate..!
Thinking about it, the wires fit directly into the pump unit and fuel sender 'through the base plate'...the two units are sealed to the base plate, and perhaps there is no live feed open to the fuel...id hope not anyway, i like my left leg in the place it was intended..lol..
AUsome, as usual
Great stuff, thanks
Well explained...new fan.....thank you.
Welcome aboard Ross, and Merry Christmas !
Cheers mate, excellent post Del Boy, clear as a bell !! Sorted !
Love the colour of your bike by the way..I have a 2008 Roadster that has the ECM under the seat in the rear fender as well - quick question for ye, what type of mono seat is that? a HD product? Keep it safe, F
Great video, thanks brother
Hi Stu.
Sadly the old Mk1 banger i have doesn't have fuel filter, and i cant remember what they look like, ive had a couple of Mk2's over the years, but never had cause to change one so id be on the dark till i looked at it.. they cant be that hard though mate, usually inline between the tap and the carbs, so easy enough to slip the hose off each end of the filter, and insert a new one... if you get stuck send me a closeup photo so i can see what it looks like, hope that helps, Del
taking all the guesswork out of it once again. thanks!
Another awesome vid. Any quick tips on how to raise the tank at its front?
cont..Use a length of correct diameter fuel hose (6mm) fuel pipe clips on all joints (so 4 off). Do not make the pipe too long or you’ll get air locks. Remove the tank and fuel/vacuum pipes. Cut the fuel pipe (I like a new pipe as the old one can be a loose fit over the spigots) fit the filter with clips then offer the over length pipe into position checking there is sufficient space for the unit and cut surplus off the pipe at either end (I like to see the filter…) TBC
Hello, could you publish one video about assembling the fuel pump on the Sporster 1200? Thank you. Keep doing your great job and videos
+Fabio法比奥 Sorry, but we cannot make video's to order...!
thank for an informative info..smile
Excellent video. I need to do this tomorrow to get a the wiring loom under the tank. I want to fit a tracker on a permanent live and wire up my Garmin Zumo on a switched live, so following a zoom is important.
On my 883 there is a cover in front of the fuse box and in there are two connectors. One goes to a sensor below the tank. My connector is disconnected a wire shorts the two pint in the other part of the connector attached to the loom. It hast a stage 1 fitted. Do you know why this sensor has been purposely disconnected?
So many variations on this mate, depending on year and specification, the way Harley design things is to have one overall wiring harness for all Sportsters and then connect up what they need and blank off what they don't, so depends on your bike, model and year, and no, I wouldn't keep that information to hand, even a Harley Master Tech would have to look that up and they'd probably have to see it first too... however, if you invest in a Genuine H-D manual, then it'll all be in there my friend, a worthy purchase... good luck with it, hope it goes well for you.
Do I need to drain the tank before removing it? Or, with the electrical disconnect I won't leak when the valve thing is removed?
lov the color of Pennys bike
good stuff guys
Great vid. Makes me want to take mine off just to do it. lol
Hey Delboy, I recently bought an 08 Nightster 1200. The previous owner put a 48 tank on it. Will the low fuel light still come on at the appropriate time? Being new to harley I was worried that it being a smaller tank the system would still think it has the bigger tank on it and somehow that would screw things up. Thanks for the help and videos!
Hi mate...your Harley tank has a plate under the left side and attached to that is the fuel pump and a big filter....they stick up into the tank and are designed to be submerged in the fuel.....so the fuel pump, (which looks a bit like a toilet roll tube) measures the level of the fuel as is drops down the side of it's body......so it doesn't matter weather the pump is sitting in your 48 tank, or a 50 gallon truck tank.....once the fuel level gets to 4 liters left, its activates the light....
Best advice if you are ever worried is to carry a fuel flask with a spare litre in it, and when the light next comes on.....zero the trip meter, and ride deliberately to run the tank dry till the bike stops....then you will for ever know exactly how many miles you have in reserve...and the spare litre will get you to a garage.. hope that helps mate... cheers, Del.
I know, WTF are they playing at designing a tank that has such silly range, but hey ho, its the most popular sportster of all time, so its hardly an own goal aye.... thanks for taking pity on our Penny, shes a good old stick, will happily skulk about in a damp cold garage with me for hours, and make tea in between shoots too aye...what a star she is.. i think ill keep her on aye..?.. cheers buddy, Del.
great info del
Nice video, only thing i would say is not to use Duct tape, instead using painters (paper tape) though a towel works better
Top notch 'how to' video!
That was so simple... my Sportster must be about the same. The last bike I had the tank off was a 1970 CB 350 that had an bridging tube and always seemed to make a mess when draining the tank. Leads to my next question. The plate needs to be pulled off to replace the fuel filter? How often should that really be done? Now, I do have a problem I woke up to. 2007 HD Sportster C, 1200 CC... I was going to ride my bike to work. But the security system activated. I tried my other key/ fob set & it still would not start... put it on a trickle charger & took the car to work. . . still will not start. Checked the fob battery 3.1 volts - ok, looked at the fuses - pulled the main first, like in your changing the battery video :-) & I did find some oxidation, so I wire brushed them & put electrical grease on them - like I user on the light bulbs. Still will not start. I looked at the Delphi connector & the ECU connector & both are clean, & now restated... still will not start. Any thoughts on this? Thank you for your videos, liked the one on ID & emergency information. NickNarcowich@Yahoo.com Sacramento, California, U.S. of A.
If this started with your security system kicking off, Nicholas, then it's probably routed in your alarm fobs... they must be replaced with the genuine H-D batteries and not the cheap kind you get from the drug store... often with many cases of this, people grab the spare fob and expect it to work, without considering that it's obviously the same age as the other one... replace them both and charge the battery and it should work fine! I've had this issue twice myself and it cured it both times - the cheap batteries are a liability, I found on the genuine H-D ones work !
cont connect pipe to carbs then fit clip at CV carbs. Refit the tank, reconnect the fuel and vacuum pipes (plus clips) start the engine and watch the clean fuel flow…
HaHa, yeah, don't give him any ideas, you now what the power of suggestion is like! Take care, cheers Pen x
ordered the o rings on line was hard to find but after changing both it worked turns out I left the bike off to long and here in texas heat got to the rings and dried them out o rings fit and back working again
Ive seen many pics of 883s with a relocated speedo to the left on the suspension bar i think it was, i really like the look it gives the bike with a straight dragbar but im very lost in how to do it, if you could give me a couple of tips or show me the procedurei would be really thankful