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Steve
Steve, Motorcycle Mechanic
Category: Motorcycle
Satisfied Customers: 6168
Experience:  30+ yrs. experience, MMI, HD technician, HD early, engine rebuild/performance, bike builder, kit bike program manager, CCI 2001-2004
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How to remove and replace fuel pump on Road King with fuel injection?

Resolved Question:

How to remove and replace fuel pump on Road King with fuel injection?
Submitted: 5 years ago.
Category: Motorcycle
Expert:  Steve replied 5 years ago.

Hi Turbo,

-Drain fuel tank through crossover hose at front of tank. remove one end of the hose and plug it. fit a short piece of tubing over the uncovered bung and drain. move fast....gas will be flying eveywhere.

-remove seat.

-purge fuel system. disconnect power to fuel pump at connector in front of the battery and start the bike. when engine stalls, operate starter for 3 seconds to remove remaining fuel.

-disconnect NEG battery cable.

-remove console from canopy.

-remove 10 ,T-20 torx screws securing canopy to tank.

-raise canopy slightly and remove yellow wire from spade contact on inboard side.

-remove canopy.

-inside the tank, lift fuel pump isopod off the 2 posts.

-cut Otiker clamp (squeeze clamp) from tubing at pump outlet on top and disconnect tubing.

-remove black and yellow wires from pump.

-remove pump

-inspect/replace as necessary.

 

install new pump in reverse order.

sounds easy but, getting the canopy off and on is a real treat! you have to deal with the fuel gauge sending unit attached to the canopy and it can get real tricky.

let me know if you need anything else.

Steve

Steve, Motorcycle Mechanic
Category: Motorcycle
Satisfied Customers: 6168
Experience: 30+ yrs. experience, MMI, HD technician, HD early, engine rebuild/performance, bike builder, kit bike program manager, CCI 2001-2004
Steve and 2 other Motorcycle Specialists are ready to help you
Customer: replied 5 years ago.
Thanks for the quick reply Steve. I would have never guessed to lift the pump up,over, and off the 2 posts.

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