The fuel filter is relatively cheap and should be replaced; not cleaned, at every specified service interval or anytime the fuel pump assembly is removed from the fuel tank. Often, blocked fuel injectors are a direct result of fuel filter neglect. Rider neglect for fuel filter replacement may be mostly due to the difficulty level of the service. For some models a specialty tool is also needed to remove the fuel door. However, a factory service manual is the most important tool that is needed to complete this maintenance procedure. A fuel door gasket or o-ring will be needed to complete the job; as well as small fuel line step clamps depending on the year and model.
It is also highly recommend to replace the fuel door retaining hardware depending on year and model. Start by purging fuel pressure from within the system. Unplug your fuel pump module connector. Start the motorcycle and let it idle until it stalls. Then, hold the start button for a few more seconds.
Now, disconnect your battery’s ground cable. When directly dealing with gasoline, this could not be more important. The fuel door is located beneath the motorcycle’s dash assembly on any model. Remove the fuel door and the fuel pump assembly. The steps for pump assembly removal vary from model to model.
The new fuel filter is often sold as a kit.
Again, depending on the year and model. The filter will often come with o-ring(s).
After the filter is replaced and the pump assembly is correctly positioned in the fuel tank with a new gasket or o-ring, secure the fuel door with new retaining hardware or with the specialty tool.
Fuel filter replacement can be a little more challenging than other Harley service points but with a service manual and the correct tools, a rider can keep his motorcycle well maintained while saving $$.