Question about 2000 Harley Davidson XL 1200 C Sportster Custom

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Fitting fuel tank

I (somehow) managed to remove the fuel line and hence tank from my xl1200c (07 model) and am now having problems reconnecting the fuel line.

how should this be done please

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  • Anonymous Mar 24, 2014

    took tank off a 2006 zonghen and didn't mark lines and not sure where to put the lines back

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Hey do you mean you removed the fuel valve if so the little nut that holds it on has both left and right hand threads start the nut on the tank and the fuel valve at the same time turning the nut clockwise will tighten it up bringing the two parts togther hope this helps

Posted on Jan 16, 2009

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Posted on Jan 02, 2017

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2 Answers

How to remove gas tank on 2003 ultra classic electric glide


1. Drain fuel tank as follows:
Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D.
Insert bolt in one end of hose and install hose clamp to
ensure that end is securely plugged. Using a side cutters, cut
clamp from one end of crossover hose beneath fuel tank.
Quickly replace crossover hose on fuel tank fitting with open
end of short hose while directing flow of gasoline from free
end of crossover hose into suitable container.
2. Remove seat.
3. Purge the fuel supply line of high pressure gas. Proceed
as follows:
a. Remove the 15 amp fuel pump fuse.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 seconds
to remove remaining fuel from fuel lines.
4. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
5. Carefully cut anchored cable strap securing main harness
bundles, console pod conduit, fuel level sender/fuel pump conduit, and fuel vapor vent tube to left side of frame backbone.
6. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws
secure console to clip nuts on the canopy bracket.
7. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment.
8. Lay a clean shop towel on forward part of rear fender.
9. Remove filler cap from neck of fuel tank. Remove console
and lay upside down on shop towel. Reinstall filler cap.
10. At top of canopy, depress button on socket side of 3-
place Mini-Deutsch connector to release fuel tank harness.
11. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
12. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect.
13. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
14. Remove fuel tank from vehicle.

Jun 29, 2014 | 2003 Harley Davidson FLHTCUI Electra Glide...

1 Answer

Runs good for a hour or two then front cyl.shuts off


Hi Anonymous, and the usual suspects are:
1. Severely discharged or damaged battery.
2. Loose, corroded or broken battery cable.
3. Alternator not charging or below normal rates.
4. Failed ignition coil, ignition/electronic module.
5. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor.
6. Faulty ignition switch.
7. Water or dirt in fuel system, carburetor or filter.
8. Fuel tank vent system plugged or gas cap not venting.
9. Fuel tank empty.
10. Fuel valve vacuum line broken or carburator vent line closed off.
11. Restricted, blocked or kinked fuel line.
12. Failed fuel pump, pressure regulator and or fuel injectors.
For a prime suspect please visit website below:
Harley Davidson Sportster error codes and how to access them
Good luck

Feb 16, 2014 | 2008 Harley Davidson XL1200C Sportster...

1 Answer

Romoving quick connect fuel line from tank of dyna 07


It's a similar system to a quick connect air line...grab the collar on the upper section and pull upward and pull downward on the fuel line fitting...

Feb 12, 2014 | Harley Davidson Motorcycles

1 Answer

2010 harley xl1200c white smoke from air filter and wont restart


Hi Neil, and the usual suspects are:
1. Severely discharged or damaged battery.
2. Loose, corroded or broken battery cable.
3. Alternator not charging or below normal rates.
4. Failed ignition coil, ignition/electronic module.
5. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor.
6. Faulty ignition switch.
7. Water or dirt in fuel system, carburetor or filter.
8. Fuel tank vent system plugged or gas cap not venting.
9. Fuel tank empty.
10. Fuel valve vacuum line broken or carburator vent line closed off.
11. Restricted, blocked or kinked fuel line.
12. Failed fuel pump, pressure regulator and or fuel injectors.
For a prime suspect please visit website below and good luck:
Harley Davidson Sportster error codes and how to access them

May 21, 2012 | Harley Davidson XL 1200 C Sportster Custom...

1 Answer

Gas keeps leaking from hose on back of gas tank


Service manual page 5-2 reflects a fuel tank hose (non fuel petcock) for CA 07 and later models located towards the rear of the tank underside and forward of the seat. Leakage is caused by the heat of the engine drying the hose which loses its elasticity over time. If the hose has adequate slack and is in good condition you can remove it, cut off the area that does not return to the original hose diameter and reinstall the hose and clamp. If there is no slack in the line purchase a replacement length at the dealer. Standard auto hose are a bit different in size and will either be lose (leaving the same leak problem) or be difficult to install with the potential of shaving some of the hose off and into the tank fitting. these smaller hoses may also constrict the proper design flow.
Good luck with your repair!

May 24, 2011 | 2004 Honda VT 750 Shadow Aero

1 Answer

No fuel getting from tank to carburetor. Cleaned and checked fuel position valve on the bottom of the tank and traced line to front junction block under the left front fender. Model not listed 1999...


the fuel line leaving tank to the box is your fuel pump,it may not be working,take the line from the tank to pump and check to see if you have fuel flow through that line,if you do reconnect it and disconnect line leaving box to carb, push start button to see if you have fuel from pump,if not,check to see if there is a vacuum line connected to pump,it may be vacuum operated,you can also just run the fuel line from tank straight to carb to see if it will start,then you will know if its your fuel pump.

Feb 23, 2011 | Suzuki ST 250 Motorcycles

1 Answer

2002 hd sportster xl1200c is not getting fuel to the carb from the gas tank, is the petcock bad?


Hi Scott, and the usual suspects are:
1. No fuel in gas tank.
2. Fuel valve not switched to on or reserve.
3. Fuel cap not venting properly.
4. Fuel filter clogged.
5. Vacuum line broken, cracked or not connected to petcock or intake manifold.
6. Fuel valve diaphram faulty.
7. Fuel line to carburator blocked or kinked.
8. Float valve needle stuck to seat.
Good luck.

Sep 25, 2010 | 2002 Harley Davidson XL 1200 C Sportster...

1 Answer

How do i remove the fuel supply lines coming off my gas tank, are these quick connect fittings? if so how do i take apart, any special tools required? it's an 01 h.d. ultra classic fuel injected model.


You may find these are factory hose fittings, they are put on with a special tool, and usualy can only be used once. Im not to sure how they come apart, but will have to be cut off somehow, and then replaced with standard hose clamps of the worm drive type.

Jun 28, 2010 | 2001 Harley Davidson FLHTCUI Electra Glide...

1 Answer

Turning off fuel for tank removal 07 1200c


If this is a carb. bike just turn the fuel petcock to off pos. Fuel injected remove left side side cover and locate fuel pump fuse start bike pull fuse bike will stall and try to start again this will depressurize the system turn key off and do not turn on again. then at the tank connection slide the connector ring up and pull the fuel line down and when you put it back together make sure you hear it click or snap into place locking them together Good Luck

May 08, 2010 | 2006 Harley Davidson XL 1200 C Sportster...

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