For any of you folks that have noticed a whistle while turning your bike on and off I found the answer. About a weekor so ago my 04 FLHRI Road King started to make a "NEW" sound. The usual winding up of the fuel pump was replaced with an added whistling sound. The bike ran fine for a few days but then the idle started to get wierd and performance was up and down. I researched the sound and even asked for help on this site. Well since I turn my own wrenches and knew the new sound could not be good so I got into it. Seems that thefuel line inside the tank that goes from the check valve to the regulator was rubbing on the inside of the tank. That in turn wore a hole in the line causing a leak and the whistel. Since this line is pressureized at 58 lbs. it just stands to reason that my performance would be hampered. What pissed me off was that Harley knows about it and didn't do anything about it! They did however modify the part with a slightly shorter line to minimize the rubbing. The line is still made like crap, only out of cheap plastic and will run you $40.00 plus clamps and the canopy gasket and 10 new Torx #20 sealing screws. Parts totalled about $63.00 To have this done would cost someone about $300 at Harley. Don't panic if when you shut down you hear a quick puff this happens allot and is not a problem. The problem is the whisteling when the pump is first turned on. You may last 6 months with this problem or 6 days.

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I didnt have the whistling, but a few weeks back, I had the same issue. The high pressure line was cracked, and instead of maintaining 55 psi, it was maintaining about 12. Started with just some idle issues, and rapidly got worse. Dealer fixed it for free.

 

You were one of the lucky ones. My 04 is out of warrenty. However I must admitt that when I mentioned it to the dealer out here by me they did know about the problem and quickly gave me the part number..

 

Of all the non sense bolt-ons, one thing that really stands out thatI see lacking on bikes that we know are going to give trouble some day is a fuel pressure guage. I sure like mine, it helps meto quickly eliminate some possibilities anytime I have a problem, this would have helped in this case also.

 

This just happened to me today on my '04 Heritage. It has about 53,000 miles on it now and after filling the tank, I heard a spraying noise inside the tank. It stopped as soon as the fuel pump quit before I started the bike. Later in the day, I noticed that it's now happening (spraying) while the engine is running. How involved is it to replace that fuel line? Can someone list the steps to take the old one out and put a new one in?
tnx..

 

anyone know what parts i need and how to fix my 04 rk just started doing this thanks

 

I had this happen to my 02 a while back as well...Quite a common problem I see.

 

did you fix it your self or take it to a stealer

 

Harley fixed the problem on my '03 under the emission's warranty which goes up to 15,000 miles. Didn't cost me a cent.

 

In the '07 user's manual the Emissions Warranty is stated as being 5 years or 18,641 miles.