How do you remove gas tank on 1994 Harley Davidson soft tail?

Answer 1

'84 through '99 Softails actually have two gas tanks. To remove them, disconnect the fuel line from the petcock and remove the clamp from the right side of the lower crossover line that connects the two tanks together at the front.

If there's fuel in the tanks, use the crossover nipples to drain them by pulling the hose from that nipple and quickly plugging the open end of the hose with a suitable plug (like a yellow wire nut), while keeping your finger on the nipple to keep gas from coming out.

Quickly add a 3-foot length of fuel line to that nipple and drain the fuel into a suitable container to reuse later. When that tank's empty, repeat the same procedure to drain the other tank. Always use extreme caution when working with flammable liquids.

While the fuel is draining, remove speedo reset knob then remove the dash by removing its center nut. Once the dash is off, disconnect one side of the upper crossover line between the tanks under the speedo.

Once both tanks are empty, remove the front lower mounting bolts (1/2" socket with an extension) and then the front upper mounting bolts (also 1/2" socket).

Inspect the rubber mounting grommets for damage and replace them if necessary (they tend to flatten out and become brittle with age). Be careful not to lose any of the large flat washers behind the mounting grommets.

Now the only fasteners holding the tanks in place are the two bolts between the tanks on the frame backbone. Remove either one (use 1/2" socket) while supporting that tank and lift the tank off carefully and set it aside (gently), then remove the other tank the same way.

Be careful not to lose either of the large flat washers under the mounting grommets. Those top washers have a tendency to fall into the large hole in the rear rocker box. Inspect the mounting grommets for damage and replace them if necessary.

To reinstall the tanks just reverse the above procedure. Replace any damaged hoses and hose clamps.