How to Change the Fuel Filter on a 2002 Harley Davidson

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Suggested maintenance for carbureted 2002 Harley-Davidsons includes checking and cleaning or changing the fuel filter every 20,000 miles or 32,000 kilometers. While this isn't a difficult task, it is necessary to drain the gas tank, which is the bulk of the job.

Things You'll Need

  • Fuel supply valve gasket
  • Fuel tank filter
  • Mity-Vac hand pump
  • Hose clamp pliers
  • Pipe sealant with Teflon

Drain the Gas Tank

  • Turn the fuel supply valve to the "off" position.

  • Remove the hose that goes to the carburetor from the outlet nipple on the left side of the fuel supply valve assembly.

  • Attach a piece of fuel line to the outlet nipple and run to a gasoline container.

  • Remove the vacuum hose from the vertical nipple on the back of the fuel supply valve assembly.

  • Turn the fuel supply valve to "reserve".

  • Connect the hand pump to the vacuum nipple using the correct adapter.

  • Apply just enough vacuum to get the fuel running through the valve. Do not apply a vacuum greater than 25 inches of Mercury (Hg).

  • Remove the pump from the vacuum nipple and the hose from the outlet nipple after the tank is drained.

Remove the Fuel Valve Assembly

  • Locate the fuel supply valve nut above the fuel supply valve handle. It attaches the assembly to the gas tank.

  • Turn the fuel supply valve nut counter-clockwise to loosen.

  • Remove the assembly from the gas tank.

Clean or Replace Fuel Filter

  • Check the fuel filter, which is the long cylindrical screen that comes out of the gas tank.

  • Use some of the gasoline to clean the filter, if you are cleaning rather than replacing the filter.

  • Replace the filter if necessary.

Reassemble

  • Coat the threads of the fuel supply valve with the pipe sealant.

  • Replace the gasket that fits under the fuel supply valve nut.

  • Insert assembly into gas tank and tighten fuel supply valve nut.

  • Reattach hoses and refill fuel tank.

References

  • "2001 Harley-Davidson Softail Models Service Manual"; Harley-Davidson Motor Company; 2001
  • Photo Credit Motorcycle Engine image by Andrew Breeden from Fotolia.com
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