I have to remove the dummy fuel tank cover to get access to the throttle cable connection and my manual doesn't explain how to remove the cover, guess it's too basic but me and three other guys can't figure it out.
I went to a local dealer and the service man explained what must be done just to replace the throttle cable. Remove saddle bags and trunk, remove seat screws in back of seat, remove gas tank cover four screws 2 each side now access can be gained to connect throttle cable end to carburetor's.
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the fuel system pressure and disconnect the negative battery cable with
a socket wrench. Remove the spare tire cover (if present) and trunk
floor so that you can open the access panel and disconnect the
electrical connection from the fuel pump.
the fuel pump's electrical connector and disconnect the quick connect
fitting from the fuel pump. Remove the fuel tank locknut using tool
07AAA-S0XA100 or the fuel tank retaining bolts with a socket wrench,
depending on the year and engine. Remove the fuel tank.
Install the new fuel pump using the items included in the kit
and be sure to replace the gasket and O-rings. Align the arrows on the
fuel tank and pump.
Complete the installation by reversing the removal procedure.
Ok, you should have two cables on your Sportster. One is the throttle cable that pulls the carb open and the other is the idle cable that acts as "safety cable" to pull the carb closed should the throttle return spring on the carb break.
To replace either or both of the cables, it will be easier to remove the fuel tank before doing so. Make sure you look at how the cable are routed from your handlebar grip to the carb. Drain the fuel and take the tank off your bike.
Now, first loosen the cable adjusters so that you have all the slack you can get in the cables. Take the two bolts out that hold the right hand switch housing halves together. Carefully lift the top half off exposing the nylon throttle sleeve. The cables are connect so that the throttle cable is to the front and the idle cable is to the rear. Work one cable at a time out of the sleeve. Be careful and do not loose the "barrel" that goes on each cable. With the cables out of the throttle sleeve, you can pull them down through the throttle housing. Then, disconnect the cables at the carb.
To reinstall the cables, do everything in reverse. Make sure you pull the throttle grip off the handlebars and apply a bit of white lithium grease to the handlebar, inside the throttle grip, and on the nylon throttle sleeve where the cables connect. Get everything assembled but just before you tighten the bolts that hold the switch housings together, slide the throttle assembly towards the center of the handlebars until it stops, then back if off about a 1/4 or 3/8 inch. Do not adjust the throttle or idle cables too tightly, you need just a bit of slack in each one or the throttle will hang. When you think you're finished, with the engine off, turn the throttle to the wide open position and release it. It should snap back to the fully closed position. If not, work with it until you get it where it does. Reinstall the fuel tank.
Caution, failure to insure proper throttle operation could cause serious injury or death. Do the job right or take it to someone that can. Your health or your life ain't worth risking for the few bucks you save.
HI. This vehicle has a fuel pump access cover located inside the trunk, under the carpet overlay. Once you have removed the carpet; the cover can be seen in the center section of the trunk bed. There are 4 retaining nuts that are holding the cover on the access hole. Remove the nuts retaining the access cover in the trunk and lift up the cover. Once the cover is removed, the fuel pump will be exposed for maintenance or replacement.
The complete fuel pump module assembly in located inside your tank under the cover.
Relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Remove the spare tire cover (if present) and trunk floor so that you can open the access panel and disconnect the electrical connection from the fuel pump.
Remove the fuel pump's electrical connector and disconnect the quick connect fitting from the fuel pump. Remove the fuel tank locknut using tool 07AAA-S0XA100 or the fuel tank retaining bolts with a socket wrench, depending on the year and engine. Remove the fuel tank.
Install the new fuel pump using the items included in the kit and be sure to replace the gasket and O-rings. Align the arrows on the fuel tank and pump.
Removal & Installation
Extreme caution should be taken when removing the fuel tank from the vehicle! Ensure that all removal procedures are conducted in a well ventilated area! Have a sufficient amount of absorbent material in the vicinity of the work area to quickly contain any fuel spillage. NEVER store waste fuel in an open container, as it presents a serious fire hazard!
This procedure will require a new fuel pump gasket for pump installation, so be sure to have one before starting.
Relieve the fuel system pressure.
Disconnect the negative battery cable.
Remove the rear seat cushion and unplug the electrical connectors from the fuel pump.
Unfasten the four pump access cover screws and remove the cover.
If equipped, unplug the pump electrical connector located under the cover.
Unfasten the fuel line clip(s) and disconnect the line(s) from the pump.
Use a fuel pump locking ring removal tool or a brass drift and a hammer to unfasten the pump locking retaining ring.
Remove the fuel pump and the gasket from the tank.
Install a new gasket and place the pump into position in the tank.
Install the pump locking retaining ring.
Connect the fuel line(s) to the pump and install the line retaining clip(s).
If equipped, attach the fuel pump electrical connection(s).
I have replaced the plug caps, wires, and coils on my three GL1000's.If it seems to happen more in the mornings or when it is wet. Start your cycle when it is dark and spray water onto the caps, wires, and coils (behind frame neck under fake tank shroud) look for sparks/arcing that might be the problem. Did you replace your fuel filter? Are the fuel lines in the tank plugged with rust? Did you replace the air cut valves and fuel pump diaphragms( old whens can be leaking or sticky)? Hope those ideas help, I'm guessing coils.
Before servicing the vehicle, refer to the Precautions section.
Properly relieve the fuel system pressure.
Drain the fuel tank.
Support the fuel tank.
Remove or disconnect the following:
Negative battery cableFiller neck from the tankShield from tank and tank strapsFuel lines and vapor hose from pumpElectrical connection from fuel pumpFuel tankFuel pump/sending unit assembly by turning the locking ring (located on top of the fuel tank) counterclockwise using a spanner wrenchFuel pump from the fuel lever sending device
Fig. View of the in-tank fuel pump assembly
Install or connect the following:
The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the sender assembly, make sure that the fuel pump strainer does not block full travel of the float arm.
Fuel pump in tank with new seal around opening
Tank and connect fuel lines and vapor hoseTank to the frame. Torque the fasteners to 33 ft. lbs. (45 Nm).ShieldFuel filler neck and clampNegative battery cable