Replacing Fuel Filter on 2007 FLHTC Harley Davidson
The fuel pump pressurizes the fuel rail/line to a high pressure in the neighborhood of approximately 58 psi. so to avoid an uncontrolled discharge or spray of gasoline, the pressure must always be bled off prior to fuel line removal and top plate removal. To do this remove the left side saddlebag and the left side cover and then remove the remove 15 amp fuel pump fuse. And then start the engine and allow the motorcycle to run until it stalls and then turn the engine over for about three seconds to remove any remaining fuel from the fuel supply line. THEN remove the maxi-fuse and reinstall the 15 amp fuel pump fuse. THEN remove the filler cap and drain fuel tank with a safe method of your choice and store the fuel or appropriately dispose of it. THEN remove the seat, the console by releasing the socket screw to release front of console from the fuel tank weldment and the hex screw to release rear console bracket from the clip nut on the rear fuel tank bracket. THEN lay a clean towel or towels on the forward part of the rear fender and lay the consoleupside down on them. Then you will need to get a special tool for Cam ring removal and installation. HD have one as part number HD-48646) which tool you will place over the top plate, aligning the four notches at the bottom of the tool with the four tabs on the cam ring. THEN get a 1/2 inch drive ratchet, install it in the tool and rotate in a counterclockwise direction until the cam ring is loose. BE CAREFUL to properly align the tool and push down on it while rotating it to loosen the ring and to control the ring because if it slips off the ting during rotation and hold both the ratchet and tool carefully so it cannot slip and slide across the fuel tank doing substantial paint damage. WHEN it is loose remove the retaining ring, insert a small plain screwdriver between the latch and top plate, depress either side of the latch, gently tug on the harness and remove the top plate by lifting it up. After you have removed the fuel tank top plate and found the ground wire spade terminal in the slot of the fuel filter shell insert the tip of a small flat blade screwdriver through the window to depress a tang, and then pull the terminal from the slot and then gently raise the locking arm and pull the U-clip from the holes in the fuel filter shell and remove the fuel filter shell from the end cap and then also remove the o-ring and filter from the fuel filter shell.
(To reinstall a new filter in the fuel filter shell seat a new o-ring on the counterbore at the top of the filter and then install the fuel filter shell over the end cap, so that the slot in the fuel filter shell engages the index pin on the end cap and then. Holding the parts together, slide the U-clip through the holes on the locking arm side of the fuel filter shell and push the U-clip until its endsexit the holes on the opposite side and then retract U-clip until contact is made with the step in the locking arm. When that is done route the ground wire from top plate TORX screw around the index pin side of the end cap and install the spade terminal into the slot in the fuel filter shell and gently tug on the ground wire to verify that the terminal is locked in place. If the ground terminal does not lock in place properly use a thin flat bladed tool to bend the tang outward slightly away from the terminal body. Then reinstall the top plate.)
THEN locate the ground wire spade terminal in the slot of the top plate, insert the tip of a small flat blade screwdriver through the window to depress the tang, and then pull the terminal from the slot. THEN depress the collars and remove the tubes from the fittings on the fuel filter shell. Move the top plate to a bench area and remove the filter (which would also be necessary it the top plate replacement is necessary and if top plate replacement is necessary, remove the fuel filter shell.
If installing a new top plate, first install the fuel filter shell. THEN inspect the seal ring at the bottom of the top plate for cuts, tears or signs of deterioration and if and as necessary, install a new seal ring with the nubs properly contacting the ring groove walls. THEN move the top plate to the motorcycle and connect the tubes to the fittings on the fuel filter shell noting that the fittings are of different sizes to prevent improper assembly such that the tube with the smaller diameter fitting runs from the fuel pump to the fuel filter housing, while the tube with the larger diameter fitting runs from the fuel pressure regulator housing to the fuel supply valve. THEN install the connector at the bottom of the top plate, route the ground wire from the top plate connector along the inboard side of the vapor valve and install the spade terminal into its slot in the top plate and lightly tug on the wire to verify that the terminal is locked in place and if it does not lock in place use a thin flat bladed tool to bend the tang outward slightly away from the terminal body so that it will lock in place. THEN install the fuel tank top plate engaging the index tab on the outer diameter in the slot at the front of the fuel tank collar, install the cam ring over the fuel tank top plate with the TOP stamp facing UP.THEN if so equipped remove the filler cap from the top plate on fairing equipped models and get an appropriate CAM RING REMOVER/INSTALLER tool and put it in place over the top plate while aligning the four notches at the bottom with the four index tabs on the cam ring and then while all the time pushing down on the tool with both hands rotate it in a clockwise direction until all four of the index tabs begins to engage with the slots in the fuel tank collar at which time insert a 1/2 inch drive ratchet into the tool and rotate the tool until the cam ring is fully installed. THEN re-install the console next by:
FLHR/C: Use caution to avoid pinching the wire harness and the vent tube. FLHX, FLHT/C/U, FLTR: Use caution to avoid pinching the wire harness, the vent tube and the overflow tube and then re-install the fuel filler cap. THEN start to thread in the socket screw to fasten the front of the console to the fuel tank weldment, start the hex screw to fasten the rear console bracket to the clip nut on the rear fuel tank bracket and alternately tighten the socket/hex screws to 36-60 inlbs (4.1-6.8 Nm). THEN re-install the seat, re-install the maxi-fuse re-install the left side cover, re-install the left side saddlebag, refill the fuel tank check to be sure there are no fuel leaks, start the engine and again inspect for any fuel leaks.
