Hi guys, I am looking for a little advice. The fuel check valve on my 02 FXSTi started leaking a week ago...no doubt the result of the bike being stored for a number of years (prior owner) no doubt poorly done as well. On inspection the O ring in the fuel line that connects to the tank had completely disintegrated, so I replaced that and eventually the fuel line as well (was not confident my new o ring job was all it could be). Now the quick connect check valve is leaking and the o ring in this piece (the piece that screws into the tank) has failed...it actually fell out with the valve. My attempts to replace the o ring are hampered by trying to do it with the valve still on the tank and I just can't get it to seal.

Anyone had any experience with this? Do I need to remove the tank and fuel pump and line to get at this valve properly or can you pull it out of the bottom of the tank and work on it that way?

Any suggestions would be appreciated.....a new service manual is in the mail but I just wanted to get opinions first.

 

cheers

 

flashman

Fark. I think you might have to pull the pump and filter out.I've read that this is a fiddly job.If you do the job let us know how you get on cheers.

smeemn, yep had to pull the pump and tank entrails to access the check valve. It was not such a bad job afterall. I found a great post on this on the US HD forum and the pictures and notes provided made it a pretty straight forward procedure. On the 02 softail the pump is attached to the top cover plate and this is fiddly to get out of the tank, and you have to be careful witht he gasket but otherwise its all pretty well thought out. Certainly a lot simpler than anything on my KTM! I found it too difficult to repair the check valve though, only because I could not be sure that the new o rings I installed would provide a proper seal, and so rather than put in new ones myself, refit the whole pump and plumbing only to potentially find it still leaked, I ordered a new valve and hose...that's tonight refit job.

cheers

Flashman I take my hat off to ya.To go in there not knowing.You should have done the o rings you never know you might have fixed it. I'll have a look at that site as my fuel filter will need replacing soon. cheers