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Old 10-03-2004, 07:20 PM   #1
'02 V-Rod #1910
bikerdave's Avatar
Join Date: Jan 2004
Location: Carpinteria, CA
Posts: 29
Exclamation Fuel Line Damage - WARNING

I'm passing on this info. to make others aware of a potential serious failure mode. It only takes about 5 minutes to investigate and could save your a$$.

I smelled raw gas on Friday morning just after I got off the freeway on my way to work. I assumed it was from the old beater pickup in front of me at the light... didn't give it a second thought. Went to go for a spin at lunch, put her into neutral, turned on the key, and my left leg got soaked with gas. Upon further inspection I found that the high-pressure fuel line (approx 60 psi) had worn through due to abrasion on the connector attached to the frame on top of the rear cylinder, under the fuse block (see photo). It unnerved me a bit; I had a bad visual of my bike going up in flames while I was riding! Fortunately that didn't happen.

The best part is that I had it fixed that day. Glad I got the extended warranty! I called the dealer, they drove out to my work, picked up my bike, took the bike and me to the service department and replaced the fuel lines immediately. The whole repair took about 30 minutes. I was pleasantly surprised they had the parts in stock. Apparently, HD had them buy a bulk lot of V-rod parts and these fuel lines were included.

The new fuel lines are shaped much nicer, they are low against the cylinder head and there's plenty of room between them and the connector. In the photo, I was pushing them down to get a good view of the damage. FYI, My bike is a 2002, ser. no. ending in 801910, so it's one of the earlier ones. Perhaps they realized this problem and changed the shape of the hoses. BTW, these hoses are about $22.00 ea. Has anyone else had this or similar problem?
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