Doc Harley Talks: How To Avoid Rust In Your Gas Tank In Harley-Davidson Motorcycles 2008 and Earlier

[@IamJunius]

Another great video Doc. Just an additional point, if you don't store your bike with the tank full, especially in winter, water will condenses in the tank. SInce water is heavier than fuel it settles in the lowest point - the cross over tube. This results in the metal fitting sitting in water, especially if the tank hasn't been drained in years, The use of a fuel stabilizer helps emulsify the water so it burns off, but draining the tank every couple of years is the best cure. It also allows inspection of the fittings..

[@LowCountryHarleyDavidson]

Thanks for sharing Marcus…Doc

[@jimmyp6443]

Fuel lines on my panhead are steel . McMaster Carr has pinch type clamps ,purchase pinch clamps pilers to install clamps .

[@thomasheer825]

Outstanding presentation Doc, this hits all brands. Have repaired numerous tanks, and have had some tanks to repair that you would actually laugh at. On a tank with rust all over the interior, I use an electrical system to remove the rust. Mix up water with about 2-4oz of washing soda per gallon. Fill the tank to the very top. Next, get a piece of old steel stock, I use what may be lying around as the sacrifice anode. Suspend the anode, insulated from the tank metal, I use a block of wood with a hole drilled in it, got a bunch of old short rebar pieces my first choice. Use a 12v battery with the Positive lead to the anode (think A+) and the tank, the cathode (think C-), sorry it makes it easy for me to remember. Suggest you take a trickle charger to the battery as it take s bit of time. After a couple of days the rust in the tank will be attached to the anode, looks like a red fuzzball. Now on the downside, if the tank has any pinholes that the rest had been sealing you will find them when you drain the tank. Have experimented with zink plating the inside of the tank, and it seems to work. Simply suspend a zink bar inside the tank with the tank Positive and the zink bar negative. Again takes a few days. Have thought of next using a hunk of copper wire after the zink to copper plate again copper + tank -. Sorry it started as a overactive mind and KZbin videos. Kind of messy but it cleans like mad if you have the time. As they say, live better chemically!

[@LowCountryHarleyDavidson]

Wow! Thanks for sharing….Doc

[@thomasheer825]

@@LowCountryHarleyDavidson Just a warning Doc, it is a mess if you make a spill. Also found that you will find a bunch of tanks that you think, "Ah there is a little rust in there, no big issue", after say 4 days you break it down and wash out the tank and check for leaks with a light, well you get the illuminated picture" Time for the soldering equipment. Hope you try it and like it.

[@grampskraka6976]

Thanks doc! Taking the tank off my 2000 ultra classic (fuel injected) to replace rocker box gaskets and the spark plug wires, will for sure replace the tube and clamps, I had no idea. Thanks again

[@wolfdog7265]

Yep, same here. Yet I’m keen on maintenance. There’s always something up for a clean and oil. If it doesn’t I sometimes make it so. 😂 Rust doesn’t stand a chance on my watch. These kind of tips are very useful.

[@grampskraka6976]

@@wolfdog7265 as Neil young said “rust never sleeps” lol

[@davidv.780]

I've always used a razor blade carefully cut coolant lines and fuel lines so you don't have to twist the hose.

[@Big88Country]

Great tip Doc! I had a 05 FLHTC that had the crossover, and it never entered my mind to do that!! Traded the old girl in about a month ago, I miss her!!!!

[@PikeyScott]

Thanks Doc. I have an 07 dyna and recently pulled the tank for a re-paint. I noticed a little bit of surface rust on the crossovers. Nothing bad. Glad I caught it when I did. In my experience, that crossover system has caused more problems than it's solved in my 16 years of ownership.

[@outlaw6849]

Thanks to you we all are getting better at taking care of our bikes.

[@GawgaCracka]

As always, great content Doc, I always try and run ethanol free fuel in my Street Glide Special, and my 1980 Super Glide, it's no compromise, always ethanol free for anything running a carb...lawnmower, weed whacked, chainsaw, etc....and when you rebuild a carb that has been run on Ethanol, you can easily see the gunk, & corrosion it creates, all for what, to increase profits while costing the consumer more...?

[@Peteslife]

Got a 2011 fatboy lo with the cross over pipe.. I discovered the pipe when I went to change the handlebars. (And yes forgot I was about to do a big job and had just filled it up) . Haha… I don’t know how those HD clamps worked so just used a hose clamp.. I love working on my own bike.. When I first got it, I looked at it and thought “I don’t know anything about this, anything I want done it will have to go to the dealer..” but a few months later And I was doing everything. Tires, handle bars, suspension adjustments, all the servicing.. Even built my own air bag lift table. Work on your own bikes, its fun. The bike has now done over 100, 000kms, (80,000km for me… (55k miles).. I have even changed my own belt. (Probably wrecked the belt due to having the belt to loose each tire change, haha)

[@LowCountryHarleyDavidson]

A great story….Doc

[@martinwall7297]

01 flht all stock 26,600mils. I'm doing it over replacing everything, the first thing I notice is the 5/16 rubber fuel lines, crossover, and petcock to carb were breaking down from the outside. handle it and your hands-fingers are covered in black rubber almost coal like stain. these are the original lines and pressure clamps. inside the tank is good as are the fule barbs, i got lucky.

[@johnholley7749]

Had a 2011 Street Bob that the crossover line on the tank. Replaced the hose and put new harley stock clamps it when i repainted it a few years ago. Messed around and sold it shortly afterwards. Miss that little hot rod. She was 100lbs lighter than the Street Glide i have now.

[@MidnightExpressMC]

You are something of a national treasure ~ certainly in this community of ours. This little detail of knowledge prompted me to /switch out the old one with the new, fancy-schmancy H-D crossover line onto my wife’s 88 inch Softail, which line and chrome covers I’ve had laying around a smiiidge too long post purchase 😵‍💫 And this way I will be able to check what condition the condition is in 😀 Thank You, Doc! From Southern California ~ Ride Forever!

[@LowCountryHarleyDavidson]

Thank you MidnightExpressMC…..Doc

[@roncoburn7771]

That’s a good one doc lots of crossovers out there

[@james6275]

Thank you Sir always a pleasure to watch your videos before work!

[@LowCountryHarleyDavidson]

Thanks for taking your time to watch…Doc

[@williwichtig9344]

Hi Doc, once again an important issue I have to check on my Dyna Fat Bob. Greetings from overseas.... And have a nice weekend

[@LowCountryHarleyDavidson]

Thanks Willie for your support….Doc

[@beauxdutaman7450]

tnx for the info ill check my service manual to see how to drain the tank and not get gas all over the engine of floor. tnx Doc

[@rykerolaoghaire8781]

Excellent info Doc! Thank you 🙏

[@petermuller7106]

I often look your videos from germany. I ride a FLTH 2008 and now i have 67000 km on it. 🤠🤟

[@LowCountryHarleyDavidson]

Thanks for watching….Doc

[@tomdean8416]

Thanx for this info. Just did this to my 04. Luckily they were in mint condition. Always store it with a full tank and stabil. Ethanol free gas as well.

[@gregrose6915]

Great tip Doc.

[@lepe7841]

Great info Doc. Ill be checking my 2001 classic.

[@schachat01]

Thanks Doc for the excellent tech tip👍

[@craigkemmerzell5741]

Thanks again Doc

[@1Bigduff]

thanks for giving me something to worry about all night tonight :). great advise!

[@LowCountryHarleyDavidson]

🤦‍♂️…..Doc

[@stevensams8341]

My 2012 fxdc had a crossover line

[@justanotherviewer52]

Thanks Doc.

[@munciebill8674]

Can you explain how the new tanks are designed so that gas can flow from right side to left side without a crossover? Head scratcher for me lol.

[@LowCountryHarleyDavidson]

The back end of the tank is the cross over area where fuel passes back and forth….Doc

[@pb68slab18]

Never had any luck with KREEM. POR-15 tank liner kit is my favorite. Also available under the Bill Hirsch label.

[@LowCountryHarleyDavidson]

Thanks for posting….Doc

[@briancunha6965]

Doc, thanks for all do to keep are Harley's running...

[@LowCountryHarleyDavidson]

Thanks Brian for your support….Doc

[@ardyrides834]

I have a 2000 model FXDWG. I should check and replace the original hose. Doc is right. I need to get a pair of pliers to remove and replace the OEM hose clamps. I too don't like the worm clamps.

[@fearsomename4517]

I agree, but damn what a pain the ass.

[@thatsmrharley2u2]

@@fearsomename4517 Aircraft clamps are the shit. Get 'em at any auto parts place.

[@stevemiller6734]

never even thought about that, I have a '91 fxr I doubt that it has ever been off, I know it hasn't since January of 1998 when I bought it. guess I have another weekend project

[@dynabungie]

That is some great info but don't forget about the Dynas they have that crossover pipe until 2017

[@bluesriderDF]

Yup, I have a '14. I hate the crossover, so annoying.

[@fratzog]

@@bluesriderDFI put a quick disconnect in my 14 Fat Bob. You need to look at those closely to make sure you get one with a check valve on both sides.

[@bluesriderDF]

@@fratzog I have some reusable clamps, but your idea is even better 👍

[@MrMcbuck48]

Thanks again, good tip. 👍👍

[@danielnichols9049]

Great advice again Doc! Thanks

[@Info-Med]

Great info as usual, Thx Doc

[@richardlennards7823]

Always good thanks

[@benjaminacott5002]

Whats the difference from early fuel injection cross over compared to the 08 and up? Will the cross overless tank fit the early fuel injection

[@ronberry5316]

That's something I would really like to know also.

[@xlrider1565]

zawesome yip! I wouldn't even consider that as being a potential problem spot. I have an '05 Wide Glide(carb'd).

[@thatsmrharley2u2]

Any time I need small clamps ie: fuel line, etc. I ask for aviation clamps that are available at any auto parts place. They work great and seal up positively.

[@LowCountryHarleyDavidson]

Thanks Hugh for the Tech Tip….Doc

[@Bikernewscanada]

Just thinkin that maybe Silver Solder to repair that. Works on refrigeration both steel and copper. WDYT

[@eddiealvarez5493]

Outstanding info...Doc!

[@LowCountryHarleyDavidson]

Thank you Eddie….Doc

[@frankmarkovcijr5459]

The best way to avoid rust in your gas tank is to have an alloy tank. A stainless steel tank is also an option. For a motorcycle as expensive as a Harley you should not have any cheap sheet metal anywhere on the bike. Stainless an alloy tanks do not rushed therefore they do not get rushed into your carburetor or your fuel injection whatever the case may be.

[@johnwerner7194]

Thanks Doc

[@jerryshay221]

Being a Harley rider for 40 yrs and a wrench just as long the only ones I've seen rotted where on bike that sat for many years with no gas in them. i would never suggest that style clamp they are not road side serviceable I've fixed many a leak on runs when some one sprung a leak. No one left behind.

[@LowCountryHarleyDavidson]

I would always hope not having to Road Side Service but I see your point…Doc

[@revealingfacts4all]

would it be advisable to put a little blue hylamar on the end of the metal tube before putting new hose back on to help keep the moisture out?

[@LowCountryHarleyDavidson]

Interesting thought 🤔….Doc

[@leonardbartley5670]

Is it not a problem with the newer bikes ? I own a 2016 Slim S should I be concerned about this ?

[@LowCountryHarleyDavidson]

If your tank has a cross over fuel line then yes…..Doc

[@wolfdog7265]

I’m convinced the screw type hose clamps don’t work well on small diameters. Especially when pressurised. You really need the Harley type clamp. Thanks Doc, 👍will check mine shortly.

[@thatsmrharley2u2]

I learned awhile back to request aircraft type clamps for fuel lines etc. Available in any car parts store. I swear by 'em.

[@rgh622]

The cross-over line is not pressurized.

[@bogiewheelman71]

I done a handlebar grip replacement on my 08 soft tail and noticed rust & crud under the rubber slip covers.

[@LowCountryHarleyDavidson]

YES!…..Doc

[@ltsgarage7898]

Take it apart. Take a brass bottle brush that will fit inside the nipple coming off the tank put it in a drill and work it in and out. Try not to go into the nipple no more than the rust. Then sand the outside to remove the rust. Once it is all cleaned up (solid silver clean metal) take a Q-tip dip it in some “POR15” and paint the inside and outside of the nipple. Gas will not eat the POR15. Then put it back together and don’t worry about it for a long time. I did mine in 2004 on my 1999 FatBoy. It hasn’t rusted again. I just removed my tank last week it is still in good shape no rust… Oh, I have the braided line with the rubber compression fitting on each end. No clamps. That area of the bike vibrates a lot. Especially when you have over a 160hp. HD and vibration go together. Get rid of all your small clamps. The clamps that Doc is talking about. You can buy a clamping tool for “PEX Tubing for water line in homes. They also make a tool to cut the clamps off incase you want to remove them. E-bay has both of the tools. You cannot buy the 1/4 inch clamps. You’ll have to buy them from Harley…

[@LowCountryHarleyDavidson]

Thanks for sharing. I would like to add, be very careful in the brush and drill. I almost ruined a tank trying to clean the inside of a nipple….Doc

[@jimkoch1040]

My 2008 Softail Custom has a crossover line.

[@3RDOOR]

Good stuff D. I’m counting on you 👊🏻🇨🇦☕️

[@samheninger505]

My father told me too never weld on fuel tanks regardless how long the fuel had been removed. I've used marine epoxy puddy,the white stuff, On leaky fuel tanks never had any issues with repairs. Still good after seven + years.Just scuff repair area and clean good with rubbing alcohol to get a good bond.I call it magic puddy it works good. It's called water weld by jb weld

[@LowCountryHarleyDavidson]

Thanks for sharing your experience!….Doc

[@robinsonsmotorcycleandauto3929]

I will weld these if anyone needs it done. I am located in Michigan. I also advise instead of using the worm drive clamps go to parts store and get the fuel injection hose clamps. They are way better if you are not going to use the OE style clamp as Doc mentioned in his hand.

[@LowCountryHarleyDavidson]

Thanks for your talent….Doc

[@ephrammaker3153]

Thanks Doc. I have a 2011 Crossbones with a crossover - does this apply to 2011’s? Or is there something about later models that fixed this issue?

[@grampskraka6976]

I have an 08 crossbones, I’m checking mine next maintenance interval for sure

[@dynabungie]

I think it's all of them with the crossover pipe I would check it regardless

[@LowCountryHarleyDavidson]

Nope it applies. Looks like my research was wrong…..Doc

[@holisecleveland2859]

Doc, I am curious, could I possibly put a little Marvel Mystery Oil in my tank as an added protection against tank rust? Respectfully, Holise pronounced Hah Liss.

[@LowCountryHarleyDavidson]

My father add Marvel to every tank in a car he owned. I have not tried in a Harley-Davidson. The amount added would be very important….Doc

[@roberttimmons5638]

Any tips on keeping the tower gasket in place long term on 2020 street bob with no mid controls? Gasket has worked its way down causing a leak.

[@gerryrandolph]

Hey doc, I have an 01 FLHTCUI that I bought a few years ago. When I went in and did the cam chain tensioners I noticed the lining in the fuel tank was peeling off. Might be an obvious answer, but just how urgent is it to reline the tank? I cleaned out all the flakes that I could but didn't reline it. Eventually I had the injection taken off and a carb put on, the indie shop that did it, did not mention the condition of the tank.

[@LowCountryHarleyDavidson]

Well now you have carb, a fuel filter in the fuel valve and an external fuel filter could allow you more time. I have see small particles clog a small low speed jet or hold the float needle open….try to plan soon. It could be a weekend project….Doc

[@tex9280]

Great advice Doc♥️💪 Living The F🤪KING Dream ❗ Safe travels 🙏♥️🐾🐾🇦🇺

[@HairyMTB]

Dodged it by one year with my 08 model 😮

[@calebdingus5277]

I have a 97 FDXWG and just found a bubble in the paint on the underside, it is leaking fuel. At what point do you recommend just getting a new tank vs trying to repair and or line. Also if you get a new tank would you line it? Thanks for your videos.

[@LowCountryHarleyDavidson]

A lot to think about. A special year or paint could factor in saving original. A tank that old or older May have several week areas. Chasing could get expensive. Depending on what company you work with, some come coated others bare. Don’t buy cheap. You may get a great deal, invest in a great paint and later find a pin hole in the welding…..Doc

[@allensmith7945]

I bought a Harley braided crossover fuel line for my 04 Road King… Didn’t fit. It was too short. The dealership wouldn’t take it back because it had been “installed”.

[@thatsmrharley2u2]

Go figure.

[@brucesantacory1390]

hey Mike, quick Question, you said at the end 2007 and earlier, but the title says 2008, and i have an 08 FLHR, should i be checking mine at my spring service ?

[@LowCountryHarleyDavidson]

Bruce, people have found I made a big mistake not including Dyna models that have a cross over well into 2016. So I suggest to you to look for a cross over fuel line.

[@19TE72]

Thats funny. I actually have my gastank off at the moment so, thanks for the tip. :) (flsts 2001)

[@michaelrickman8560]

Hey doc if the screws are stripped on your frocks how can you get them off

[@LowCountryHarleyDavidson]

Frocks? Seems there is a nut loose behind the handlebars 🤷‍♂️….Doc

[@v-rodder2136]

While you have it off …. Good idea to put a tee at the lowest point and a valve you can easily bleed water from …. Water always goes to the lowest point

[@LowCountryHarleyDavidson]

Interesting point🤔….Doc

[@remedialone6987]

my 2016 dyna has a crossover line

[@Timeline916]

I have a 2015 switchback, I see a crossover tube ? Aren’t I ?

[@michaelhoersch6626]

My Switchback is a 2016 and yes, they do have a crossover tube.

[@davidgriego8722]

I hope those younger mechanics working with you appreciate the opportunity to learn from you!!

[@LowCountryHarleyDavidson]

They do David….Doc

[@Grunt49]

'09 FXDC has been sitting too long.

[@MetalWind]

You state that in 2008 they got rid of the fuel crossover line. My 2017 fxdb has it

[@LowCountryHarleyDavidson]

Thank you for that correction 👍….Doc

[@roadglide1745]

Remove clamp. Slice rubber tube long ways with sharp blade/utility razor blade. Should open up rubber, twist right off. Works on car/truck radiator and heater hoses. RIDE SAFE

[@werberderber6209]

That's what I did, a lot easier than trying to twisted the hose off.

[@albertstabelli5869]

Hi Doc, I have a 95 Dyna convertible that the tank liner is peeling and coming loose. What do you suggest?

[@thatsmrharley2u2]

@@albertstabelli5869 Get a new tank and DON'T use a liner on it.

[@roadglide1745]

@@thatsmrharley2u2 HD factory put liner in my new 09 FXSTC, some has peeled up. You can see it right under filler opening. Not floating around.

[@thatsmrharley2u2]

@@roadglide1745 It will eventually. I have never had any luck with tank liners. I live in the northeast and keep my tank full with StaBil added in winter and it's been fine.

[@Dinoxt12]

Extra Special Tip.

[@kennethanderson1685]

❤❤❤❤

[@pedlpower]

"Whatchya do? It was fine until you touched it!" Everett Sinjya

[@LowCountryHarleyDavidson]

That’s what many customers say…..Doc

[@chip9832]

Jb weld😂

[@Marty59143]

POR 15 inside and out.

[@SuperOperator4]

I hope that fuel tank was junk. I'd never lay one on it's side with a towel under it...

[@LowCountryHarleyDavidson]

Dented….Doc

[@gary0184]

Ok Doc, I put my 2003 RK Ann Ed in storage about 2014. I believe, I drained all the gas at that time. Was that the right/wrong thing to do? What do I do now? 2023.

[@LowCountryHarleyDavidson]

PRAY 🙏……Gary a 2003 in storage since 2014! I don’t know the condition of the bike, I have heard too many stories of dealers not offering to work on a bike that old. My list of what I would do is too long to post here. I hope you can find a professional who knows how to wake a sleeping beauty……Doc

[@gary0184]

It’s in pristine condition. Only 11,000 miles. NO apparent rust. I must have left it with a 1/4 tank of fuel. In hindsight, I guess I should’ve left a full tank of gas in there, even though that would’ve gone bad by now. Thanks for the reply.

[@markblanc5993]

Laughs in sportster

[@exupakias]

Thank you, i am gonna do it today.

[@LowCountryHarleyDavidson]

Best of luck!…..Doc

[@stevenpierce4359]

I have a 2014 sportster 500 mile on it what would you recommend to get it running sir

[@LowCountryHarleyDavidson]

Too much to explain and talk about. Take it to someone you trust….Doc