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[FUZZNUTS]

I have to change my plug wires on my 03 SERK. Where do I start? Lift the seat first and then the tank? How much crap is involved in lifting the tank. Any advice would be appreciated 

[skreminegul07]

I have to change my plug wires on my 03 SERK. Where do I start? Lift the seat first and then the tank? How much crap is involved in lifting the tank. Any advice would be appreciated 

Remove seat

Most important step is to disconnect the fuel line fitting, if not you will break the plastic fitting.  The assembly costs $50, I know.
Pull down the chrome sleeve on the fuel line where it meets the tank (left rear) and the line will pull out of the connection and won't leak (much).

Remove the screws holding the console one front, one rear, lay the console back onto some soft padding where the seat used to be.  You may have to unplug the vent hose and the sending unit wires from the tank.

Loosen the fuel tank front bolt, horizontal right at the steering neck.  Remove the bolt at the rear of the tank where it meets the seat.  The tank will now pivot up out of the way.  Be sure to put some padding on the front of the tank, as the chrome nacelle where the aux light switches are found get real close to the tank as you lift it up.  Have someone watch it while you lift. You can place a 2x4 block to hold it while you work. 

[grc]

Make the entire thing easier by running the gas down as low as possible first.  Gasoline weighs roughly 6 lbs. per gallon, so you don't want to start with 30 lbs. in the tank.  After that, follow skreminegul07's instructions to pivot the tank up at the rear.  Just loosen the two front tank bolts (one on each side), and remove the rear tank bolt.  If you need a little more room, you can remove the front two bolts and move the tank back and up.  You will have to finess the crossover hose past the coil if you take this approach, but once that is done you can tilt the tank up higher without hitting anything at the steering head area.

Jerry

[VANAMAL]

remove the fuel pump fuse and run it until it dies and you will have no pressure at the quick release fitting

[FUZZNUTS]

Thanks, I'll let you guys know how I made out. Going down the shore this wknd, my fathers 75th B day. So I won't tackle this untill sometime next week.

[FUZZNUTS]

Well I got home early on Sunday and took the seat and tank off. If there is any H.D. mechanics or anyone else that enjoys doing this type of work, God bless ya. What a pain in the ass. It took me about 4 1/2 hours to change the plug wires and plugs. I also had some of those LED lights under the tank to contend with also. I installed a set of 10 mm Screamin eagle wires and some H.D. plugs.  I road tested it and no problems. Thanks for all the advice.

[Fired00d]

Well I got home early on Sunday and took the seat and tank off. If there is any H.D. mechanics or anyone else that enjoys doing this type of work, God bless ya. What a pain in the ass. It took me about 4 1/2 hours to change the plug wires and plugs. I also had some of those LED lights under the tank to contend with also. I installed a set of 10 mm Screamin eagle wires and some H.D. plugs.  I road tested it and no problems. Thanks for all the advice.

Ain't that the truth!!!! I've got some orange plug wires that have been waiting to be installed for several years because getting my big hands up under the tank to install them wasn't working for me. I could get the tank up, but it wasn't enough room for me to get my hand under there to remove wires from coil and put the wires back in clips as they came from factory (I know I'm anal, but if it's going to be done I want it done right).

 
Ride Safe,
Fired00d
 

[FUZZNUTS]

Well those clips won't hold those 10mm wires, IMHO.  I would say that the replacements were three times as thick. And when I removed the clips they broke anyway. I guess 6 yrs old and all that heat made them brittle. The new plug wires are fit pretty snug and snaked thru the other exsisting wires and cables under the tank. No chance to sag.