Topic: Do I need to remove the tank? (Read 4985 times)

deaf1 · « **on:** February 14, 2009, 07:12:43 PM »

2008 Serk...

I am putting some new electric goodies on the bike (Howard Horns, MotoPort Light)

With the horns, I have to run a new ground wire from the horn to the battery, should I remove the tank or is there a better way.

With the MotoLite's, gotta run wire front to rear... Same thing as above...

I have NO idea how to take the tank off or if I should even attempt it... I just read on another forum details for tank removal.... I am not gonna touch that... Any way to fish wires under the tank or ther ideas?

Scott

Twolanerider · « **Reply #1 on:** February 14, 2009, 07:30:15 PM »

Quote from: deaf1 on February 14, 2009, 07:12:43 PM

2008 Serk...

I am putting some new electric goodies on the bike (Howard Horns, MotoPort Light)

With the horns, I have to run a new ground wire from the horn to the battery, should I remove the tank or is there a better way.

With the MotoLite's, gotta run wire front to rear... Same thing as above...

I have NO idea how to take the tank off or if I should even attempt it... I just read on another forum details for tank removal.... I am not gonna touch that... Any way to fish wires under the tank or ther ideas?

Scott

Personally I like to pop the tank off rather than fishing something underneath it. Just so can use wire ties to strap it down well and in a way that will lay well in the space. But it's by no means a necessity. Especially when you've already decided you're not taking the tank off.

Loosen the two bolts in the front. Remove the bolt in the rear. Raise the rear of the tank and put an appropriately sized socket or other item in the gap created to hole the rear of the tank up.

WATCH THE DASH AND FRONT OF THE TANK AS YOU'RE RAISING THE REAR. DON'T BANG IT IN TO THE FAIRING.

With the rear of the tank up fish a piece of mechanics wire or anything else stiff enough to work it from one end to the other. Tape the wires you wish to pull to the end of your fish. Pull them through. Voila...

deaf1 · « **Reply #2 on:** February 14, 2009, 07:33:14 PM »

Thx!!!

Any idea where the horn wires come up thru? I need to run a bigger ground for the air horns.. I would like to use the exsisting path, but I cant seem to find it...

Scott

sadunbar · « **Reply #3 on:** February 14, 2009, 07:33:54 PM »

Quote from: deaf1 on February 14, 2009, 07:12:43 PM

2008 Serk...

I am putting some new electric goodies on the bike (Howard Horns, MotoPort Light)

With the horns, I have to run a new ground wire from the horn to the battery, should I remove the tank or is there a better way.

With the MotoLite's, gotta run wire front to rear... Same thing as above...

I have NO idea how to take the tank off or if I should even attempt it... I just read on another forum details for tank removal.... I am not gonna touch that... Any way to fish wires under the tank or ther ideas?

Scott

I wouldn't let someone else's experience scare you off...It really is not that difficult...

sadunbar · « **Reply #4 on:** February 14, 2009, 07:35:27 PM »

Quote from: sadunbar on February 14, 2009, 07:33:54 PM

I wouldn't let someone else's experience scare you off...It really is not that difficult...

And once you have done it - it will seem easy - and then you can move on to something more difficult - and before you know it - you will be an expert telling others how easy things are!

Twolanerider · « **Reply #5 on:** February 14, 2009, 07:39:29 PM »

Quote from: deaf1 on February 14, 2009, 07:33:14 PM

Thx!!!

Any idea where the horn wires come up thru? I need to run a bigger ground for the air horns.. I would like to use the exsisting path, but I cant seem to find it...

Scott

Quite frankly why worry about it? If you remove the horn cover it's a lot easier to see where the horn's harness goes back under to meet the larger harness. But there's no reason to follow any existing path for a new run. You can do it in a way that's still well hidden and much easier. If you need a bigger ground that goes somehere in the area of the existing horns just go straight to the battery negative. Use black wire so it's not noticable, wire tie it to the frame tube under the tank as it comes forward. Simple and easy. Especially when you don't want to pull the tank to see all the existing harness to begin with.

Twolanerider · « **Reply #6 on:** February 14, 2009, 07:41:01 PM »

Quote from: sadunbar on February 14, 2009, 07:35:27 PM

And once you have done it - it will seem easy - and then you can move on to something more difficult - and before you know it - you will be an expert telling others how easy things are!

Ever get your pushrod tubes taken to the bench grinder

?

(some people do things even if they don't fit!)

sadunbar · « **Reply #7 on:** February 14, 2009, 07:43:15 PM »

Quote from: Twolanerider on February 14, 2009, 07:41:01 PM

Ever get your pushrod tubes taken to the bench grinder ?

(some people do things even if they don't fit!)

ummmm......no......but I know someone who did!

grc · « **Reply #8 on:** February 14, 2009, 07:44:12 PM »

Quote from: sadunbar on February 14, 2009, 07:33:54 PM

I wouldn't let someone else's experience scare you off...It really is not that difficult...

Removing the tank on the '08/'09 models should be a piece of cake, since there isn't a fuel crossover line like the one on the older models. Suggestion: Run the fuel down as low as possible, or use a syphon to suck out as much as possible. This makes the tank much lighter and easy to handle. Then just follow the instructions in the shop manual and be careful not to drop the tank or bang it into something.

Jerry

Twolanerider · « **Reply #9 on:** February 14, 2009, 07:55:38 PM »

Seriously Scott (not Scott D but Scott thread starter), pulling the tank isn't a big deal. Have to wonder from your first description if the friend who described the process to you perhaps has a bike older than yours?

If he described the fuel crossover line in the front of the tank, draining fuel and all those hassles you won't have those. After you've done it once you'll find that removing the tank on your bike is about a ten minute chore once the seat is off. You don't have to deal with the crossover line or mess with fuel at all other than a drip or two from the quick disconnect on the line at the bottom of the tank.

If you just don't want to mess with it you obviously don't have to. But it's not a big deal at all if you decide to tackle it.

deaf1 · « **Reply #10 on:** February 14, 2009, 08:04:58 PM »

What worried me was all the electric connections, the gauges etc.... Anyone in chicago that wants beer and pizza??

The horn run prob doesnt need to go thru the tank wiring tho...

Here is the thread I was looking at..... http://www.hdtalking.com/touring_models/10507-tips_for_tank_removal_on_an_08_road_glide.html

Also, being on one crutch still, I dont want to drop the damm tank!!!

Scott

Twolanerider · « **Reply #11 on:** February 14, 2009, 08:13:29 PM »

Quote from: deaf1 on February 14, 2009, 08:04:58 PM

What worried me was all the electric connections, the gauges etc.... Anyone in chicago that wants beer and pizza??

The horn run prob doesnt need to go thru the tank wiring tho...

Here is the thread I was looking at..... http://www.hdtalking.com/touring_models/10507-tips_for_tank_removal_on_an_08_road_glide.html

Also, being on one crutch still, I dont want to drop the damm tank!!!

Scott

The nearly empty tank doesn't weigh much. But you do need enough balance lean over it to lift it straight off. Add about 6.5 pounds per gallon for however much fuel is in the tank. On a bad leg could certainly understand the concern.

Your Road King's tank is actually a (tiny) bit more of a hassle to remove than a Road Glide or Electra Glide. Just because of extra instruments on the dash. But you'll not find a lot of small individual leads or plugs though. Big plug that only fits one way and only just a bit else.

Do whatever you're most comfortable with though. Fishing a couple of small leads beneath the tank really won't hurt a thing. It's done often. And you can always lift the tank later when the leg is better to tie them down better if you want to.

sportygordy · « **Reply #12 on:** February 15, 2009, 12:34:46 AM »

Prior to 2008 models, i used to dread removing the tanks. The tank mounting on 2008-2009 models have changed, whereby tank removal is painless and quick.

Twolanerider · « **Reply #13 on:** February 15, 2009, 03:02:01 AM »

Quote from: sportygordy on February 15, 2009, 12:34:46 AM

Prior to 2008 models, i used to dread removing the tanks. The tank mounting on 2008-2009 models have changed, whereby tank removal is painless and quick.

I've always cheated on my own. For years have always put a quick disconnect in the crossover line of any bike I had. Makes them simple also.

deaf1 · « **Reply #14 on:** February 15, 2009, 10:41:56 AM »

So no one lives near chicago and wants to help out a poor guy on crutches???

All the beer you can drink (after the install)

Thx for all the help on the details, I may just lift it off a little , as my balance isnt the best right now... Still on a crutch after got t-boned!

Scott

deaf1 · « **Reply #15 on:** February 22, 2009, 10:16:54 AM »

Finally tried to get the tank lifted up... There doesnt seem to be and good way to get wired and a larger loom (for the motolights) in there w/o taking the tank off.

Other then the 4 bolts, what else will I have to disconnect? There is the loom that goes to the cluster, and a few things I can kinda see under the tank. I dont know why I didnt have the dealer do this when it was in for service for the alarm, but I had a brain fart....

Thx
Scott

103_RK · « **Reply #16 on:** February 23, 2009, 06:33:04 AM »

Just remove the chrome dash that covers the center of the gas tank (the part where the spedometer mounts). there is a channel there to run wires through. You don't need to remove the tank. At least it's that way on my 03 SERK.

Sean M Cary · « **Reply #17 on:** February 23, 2009, 08:02:23 AM »

Quote from: 103_RK on February 23, 2009, 06:33:04 AM

Just remove the chrome dash that covers the center of the gas tank (the part where the spedometer mounts). there is a channel there to run wires through. You don't need to remove the tank. At least it's that way on my 03 SERK.

103 - I need to take mine off this week to run wire for my Zumo, is there a gasket in there that I need to replace if I take this off?

Not at home, or I would just look in my manual.

Sean

deaf1 · « **Reply #18 on:** February 23, 2009, 08:38:34 AM »

Quote from: 103_RK on February 23, 2009, 06:33:04 AM

Just remove the chrome dash that covers the center of the gas tank (the part where the spedometer mounts). there is a channel there to run wires through. You don't need to remove the tank. At least it's that way on my 03 SERK.

That would ROCK! I havent been in the garage (freezing) But what do I need to get the instr. cluster off?

Scott

Twolanerider · « **Reply #19 on:** February 23, 2009, 10:48:23 AM »

Quote from: Florida Marine on February 23, 2009, 08:02:23 AM

103 - I need to take mine off this week to run wire for my Zumo, is there a gasket in there that I need to replace if I take this off?

Not at home, or I would just look in my manual.

Sean

There is a rubber gasket that is the interface between the dash and the tank Sean. Actually seals nothing though. Just there to avoid the metal on metal contact. You don't replace it.

Twolanerider · « **Reply #20 on:** February 23, 2009, 10:50:26 AM »

Quote from: deaf1 on February 23, 2009, 08:38:34 AM

That would ROCK! I havent been in the garage (freezing) But what do I need to get the instr. cluster off?

Scott

Two fasteners. Both out in the open and obvious. One center high between the speedo and ignition switch and one center low just above the seat. The lower one might have the head of the fastener hidden by a decorative bezel that is commonly used. Taking the dash off is half the battle of tanking the tank off.

Talon · « **Reply #21 on:** February 23, 2009, 01:54:37 PM »

I would do like 2LR is saying, just remove the rear mounting screw and loosen the front two. It's not major work to take the tank off, but a pain! Have to drain it, remove hoses, take the dash out to get to the wiring. I'd try it first and see. I just ran new throttle and clutch cables. I did the reverse for the throttle cables. left the back screw loose, and pulled the front two, it gave me enough room to get in and route the cables even with the crossover hose still connected. Some times you just need to get in there and see what works for you. Good luck.

Craig

J-Carr · « **Reply #22 on:** February 24, 2009, 10:46:56 AM »

Can I just add that lifting the tank too far without disconnecting the fuel line can break the plastic nipple at the injector side... At least on a Dyna. Can I also add that trying to finagle it back together afterwards unitl an overpriced replacement peice comes in from HD can cause the bike to break down on the side of the road and piss you'r wife off really bad. Don't ask how I know this... I'm not tellin!

My recolection is that draining the tank prior to removal isn't necessary other then for weight reduction on a fuel injected bike. When you pull the injector fuse and run the bike til it stalls it will have eliminated the preasure and the valve in the tank where the petcock used to be won't open. So the gas stays in. Right?

Ride Safe,
J-Carr

Twolanerider · « **Reply #23 on:** February 24, 2009, 10:56:35 AM »

Quote from: J-Carr on February 24, 2009, 10:46:56 AM

So the gas stays in. Right?

Ride Safe,
J-Carr

On a newer tank without the external fuel crossover line that's correct JC. With the crossover you'll either have to drain fuel or have put a quick disconnect in the line first. If the tank is coming off I've often not drained it on the bike though. Couple of small vice grips or large forceps; one close to the tank nipple on each side. Cut the hose in the middle. Stick a bolt in each side. Take off the vice grips or forceps. Lift away. With the tank away from the bike you can then more easily drain the lines in to a gas can and then install your new line with a disconnect in it

.

J-Carr · « **Reply #24 on:** February 24, 2009, 11:00:34 AM »

Quote from: Twolanerider on February 24, 2009, 10:56:35 AM

On a newer tank without the external fuel crossover line that's correct JC. With the crossover you'll either have to drain fuel or have put a quick disconnect in the line first. If the tank is coming off I've often not drained it on the bike though. Couple of small vice grips or large forceps; one close to the tank nipple on each side. Cut the hose in the middle. Stick a bolt in each side. Take off the vice grips or forceps. Lift away. With the tank away from the bike you can then more easily drain the lines in to a gas can and then install your new line with a disconnect in it .

Thanks Don,

That was my recollection as my son and I lifted the tank off together from each side so the weight wasn't an issue. I thought it was much easier then fishing wire and I know it's all tied down nice and neat under there.

Ride Safe,
J-Carr

Twolanerider · « **Reply #25 on:** February 24, 2009, 11:05:39 AM »

Quote from: J-Carr on February 24, 2009, 11:00:34 AM

Thanks Don,

That was my recollection as my son and I lifted the tank off together from each side so the weight wasn't an issue. I thought it was much easier then fishing wire and I know it's all tied down nice and neat under there.

Ride Safe,
J-Carr

That's what I prefer also JC. Just like making sure cabling or wiring won't later develop a rub and is tied in place where I want it. I also never cared for draping wiring over the tank under the dash. Since the tank does need to come off occasionally it's just that much more in the way when it does. Just easier to do it once, do it right and have done it that way the first time. Then never have to think about it again.

I've had mine on and off several times even when full of fuel. With the quick disconnects in the crossover just never worry about fuel loads. They aren't so heavy nor so wide that they're actually difficult to handle.

Talon · « **Reply #26 on:** February 24, 2009, 11:25:45 AM »

Yea, but like you said, if you don't have the disconnect on the crossover, you do have to drain the tank, not a big deal, but I was able to get the tank high enough so I could see the lower half of the top frame tube and cable looms, it was easy, I would assume you could do the same on the other side, didn't really look.

J-Carr · « **Reply #27 on:** February 24, 2009, 11:30:51 AM »

Quote from: Talon on February 24, 2009, 11:25:45 AM

Yea, but like you said, if you don't have the disconnect on the crossover, you do have to drain the tank, not a big deal, but I was able to get the tank high enough so I could see the lower half of the top frame tube and cable looms, it was easy, I would assume you could do the same on the other side, didn't really look.

Actually, I never did drain it on my old bike or on now on my wife's Dyna. I run the fuel out by pulling the fuse and running until it stalls so the preasure's off the tank. Then clamp off the hose with Vise Grips on one side. Pull the line from the other side and quickly slide a spare hose that's plugged onto the open nipple. Spill no more fuel then we do draining it. Don't even need to clamp it to get it stay. When we're finished we just lide it back on. We replaced the crimp clamps with screw clamps to make it easier.

Ride Safe,
J-Carr

Author Topic: Do I need to remove the tank? (Read 4985 times)

Sean M Cary