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Old 10-03-2004, 08:20 PM   #1
bikerdave
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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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Old 10-03-2004, 11:06 PM   #2
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So far, not from the smell check. Mine was built May '02, bought her July '02. Thanks, I better check.

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Old 10-04-2004, 12:06 AM   #3
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Same here, I'll check tomorrow! Thanks!
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Old 10-04-2004, 06:19 AM   #4
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Bikerdave I made this a sticky and hope that everyone will take a minute and inspect the lines at that point. Thanks for the heads up on it. I'll check the lines on both of mine asap.



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Old 10-04-2004, 07:12 AM   #5
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The connector is your speed sensor. As far as the rubbing, I can't see this. There should be no movement in this area. Check your front motor mount. Later Ski.
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Old 10-04-2004, 08:36 AM   #6
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Thanks Dave for the heads up. I have an 02 and will be checking this today. Which line specifically was shooting the fuel? Are they both fuel lines?

Thanks again for the good post.
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Old 10-04-2004, 08:56 AM   #7
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Checked mine, all OK have a good 1/2" or more of clearance. Thanks for the warning though.
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Old 10-04-2004, 10:46 AM   #8
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Thanks for the heads up.
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Old 10-04-2004, 11:17 AM   #9
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Mine is worn through the covering, looks like it is rubbing the inside coil pack bolt on the back cylinder. Is this the same spot that you guys are seeing ?

Mine is a 03 buit 09-02

Thanks for the info!!!!!
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Old 10-04-2004, 11:17 AM   #10
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If this starts showing up on multiple bikes then this would be a good candidate for a safety recall. If you have this fixed save your receipts. If a recall happens you should get reimbursed.
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Old 10-04-2004, 11:29 AM   #11
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I wrapped them with some hose. It should have a clip coming off the valve cover bolt to hold them in place. Everyone knows engine vibration will chew through anything.
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Old 10-04-2004, 11:39 AM   #12
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Okie.... That looks like a good fix, like to see the motorship come up with something here. I'll have to dig through my junk a rubber bond clamp would work good here... Okie... CLEAN off those cam covers!
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Old 10-04-2004, 11:43 AM   #13
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Rodger that.
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Old 10-04-2004, 12:24 PM   #14
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Hey all, could you please post a photo a little further back? Am having trouble figuring out where to look.

Thanks
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Old 10-04-2004, 12:46 PM   #15
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Greg.. Take the air box cover off and lift the fuse block up, under this look just left of rear coil pack and you will see two fuel lines running over the rear cam cover. It seems that the coil pack or bolt is causing this. Hope this helps.Good luck Greg
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