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Preface
The problem began on July 26, 2009. My 2007 Street Bob was now (of course) just past its
2 year warranty and I had put about 35,000 kilometers on it by that time.
Returning to the city after a long day's ride to Grande Prairie and back, the
bike began back-firing loudly as I let off the throttle and, when coming to a stop at the first street
light, the motor just died, not able to idle unless I kept the revs up by holding the throttle.
This was strange because the bike ran quite well once under way, as it had been on the highway the
whole time that day.
So thus began the search for the cause of the problem because this poor-running condition persisted from that time
on. Eventually at my wits end, I brought the bike to the dealership. For awhile, they were puzzled as well. But one
thing sorta tipped the head technician off: there was a strange noise inside the gas tank - like
it was spraying inside there. Knowing that year's Dynas (2007) were prone to internal fuel line leaks, he did a fuel
pressure check. Sure enough, instead of a fuel line pressure of 50-55 psi, my bike's pressure was
only 20 psi.
Asked when I would like to bring the bike in for them to fix it I replied,
"Thanks but, at your $100 dollar per hour shop rate, that won't be necessary - now that I know what
to replace!" Hence the write-up you see here.
As an aside, when the tech at the dealership remarked that he was tipped off by the strange noise
inside the tank, I immediately knew what he was referring to. I had heard it too, but only
occasionally and hadn't connected the dots - like the fact the tank was low on fuel at the time
and the thing it could be indicating (i.e. gas spraying out of the exposed line, likely making a sound as
it hit the inside of the tank when not submerged). Something for the reader to keep in mind perhaps.
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The photos below cover the main aspects of work done, but do not capture each detail in the process.
This page is aimed at providing a pictoral record (useful during re-assembly) and the remarks tend to
focus on parts of the work performed that seem less obvious from reading the Service Manual. The reader
is advised to have a Service Manual handy, prior to attempting this work. Click on any of the photos
below to view higher resolution versions, if you need finer detail.
And... need I say it is not a good idea to be smoking a cigarette while doing this?
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After expelling pressure, disconnect fuel line
Lifting collar on tank base releases line
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Remove console, protecting tank
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A couple of shots, showing the wiring packing as connectors are taken apart.
As photo on right shows, one end of wiring is hooked down by speedometer housing.
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A couple more shots, showing speedometer's housing being removed.
Housing removed to free wiring. Pry up housing with screwdriver for tabs to release.
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Removing connecters under console
Still attached in this photo, the gas vent hose can
also be removed at this time.
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Draining gas from tank
Although the Service Manual states a 5/16" I.D.
hose should be used to plug one outlet, a
slightly smaller I.D. would be better.
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Tanks removed. Let's drink some beer!
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Kitchen work table for removing innards
This part of the work can get tricky while trying to wiggle
parts out of the tank, so better get yourself comfortable.
|
Disconnecting internal fuel line
|
New and old fuel filter with 40,000 kms
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Fuel pump removed, ready to be fitted
with new pickup screen
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Putting console back on - tight space with the wiring
|
Preface
The problem began on July 26, 2009. My 2007 Street Bob was now (of course) just past its
2 year warranty and I had put about 35,000 kilometers on it by that time.
Returning to the city after a long day's ride to Grande Prairie and back, the
bike began back-firing loudly as I let off the throttle and, when coming to a stop at the first street
light, the motor just died, not able to idle unless I kept the revs up by holding the throttle.
This was strange because the bike ran quite well once under way, as it had been on the highway the
whole time that day.
So thus began the search for the cause of the problem because this poor-running condition persisted from that time
on. Eventually at my wits end, I brought the bike to the dealership. For awhile, they were puzzled as well. But one
thing sorta tipped the head technician off: there was a strange noise inside the gas tank - like
it was spraying inside there. Knowing that year's Dynas (2007) were prone to internal fuel line leaks, he did a fuel
pressure check. Sure enough, instead of a fuel line pressure of 50-55 psi, my bike's pressure was
only 20 psi.
Asked when I would like to bring the bike in for them to fix it I replied,
"Thanks but, at your $100 dollar per hour shop rate, that won't be necessary - now that I know what
to replace!" Hence the write-up you see here.
As an aside, when the tech at the dealership remarked that he was tipped off by the strange noise
inside the tank, I immediately knew what he was referring to. I had heard it too, but only
occasionally and hadn't connected the dots - like the fact the tank was low on fuel at the time
and the thing it could be indicating (i.e. gas spraying out of the exposed line, likely making a sound as
it hit the inside of the tank when not submerged). Something for the reader to keep in mind perhaps.
|
|
The photos below cover the main aspects of work done, but do not capture each detail in the process.
This page is aimed at providing a pictoral record (useful during re-assembly) and the remarks tend to
focus on parts of the work performed that seem less obvious from reading the Service Manual. The reader
is advised to have a Service Manual handy, prior to attempting this work. Click on any of the photos
below to view higher resolution versions, if you need finer detail.
And... need I say it is not a good idea to be smoking a cigarette while doing this?
|
After expelling pressure, disconnect fuel line
Lifting collar on tank base releases line
|
Remove console, protecting tank
|
|
|
|
A couple of shots, showing the wiring packing as connectors are taken apart.
As photo on right shows, one end of wiring is hooked down by speedometer housing.
|
|
|
|
A couple more shots, showing speedometer's housing being removed.
Housing removed to free wiring. Pry up housing with screwdriver for tabs to release.
|
Removing connecters under console
Still attached in this photo, the gas vent hose can
also be removed at this time.
|
Draining gas from tank
Although the Service Manual states a 5/16" I.D.
hose should be used to plug one outlet, a
slightly smaller I.D. would be better.
|
Tanks removed. Let's drink some beer!
|
Kitchen work table for removing innards
This part of the work can get tricky while trying to wiggle
parts out of the tank, so better get yourself comfortable.
|
Disconnecting internal fuel line
|
New and old fuel filter with 40,000 kms
|
Fuel pump removed, ready to be fitted
with new pickup screen
|
Putting console back on - tight space with the wiring
|
|
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