Replacement Fuel Gauge Sending Unit
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Tourer
Joined: Aug 2014
Posts: 302
Likes: 49
From: Gambrill, MD
Replacement Fuel Gauge Sending Unit
Hey folks!
I haven't finished my troubleshooting yet, but I suspect that the fuel gauge sending unit on my 1993 Ultra (P/N 75040-88) isn't working. I've been searching online for new unit, but the best I've been able to find so far is one on eBay that looks to be in questionable condition. Is there a modern replacement for this unit that's more readily available?
Thanks in advance!
Dave
Crofton, MD
I haven't finished my troubleshooting yet, but I suspect that the fuel gauge sending unit on my 1993 Ultra (P/N 75040-88) isn't working. I've been searching online for new unit, but the best I've been able to find so far is one on eBay that looks to be in questionable condition. Is there a modern replacement for this unit that's more readily available?
Thanks in advance!
Dave
Crofton, MD
Seasoned HDF Member
Joined: Jul 2014
Posts: 8,590
Likes: 3,361
From: Cental, MI
Someone recommended this unit to me not long ago
https://www.ebay.com/itm/Oil-Gas-Fue...53.m1438.l2649
... no, I have not tried it...
then someone else claims to have used this!!!
https://www.ebay.com/itm/2-52mm-Univ...53.m1438.l2649
Tho I cannot see how that second one can mount??
Good luck, and post back any solutions..
https://www.ebay.com/itm/Oil-Gas-Fue...53.m1438.l2649
... no, I have not tried it...
then someone else claims to have used this!!!
https://www.ebay.com/itm/2-52mm-Univ...53.m1438.l2649
Tho I cannot see how that second one can mount??
Good luck, and post back any solutions..
Grand HDF Member
Joined: Apr 2007
Posts: 3,725
Likes: 3,070
From: Brighton, MI
If you plan on using the oem gauge, the ohms resistance values need to match your gauge. Sorry, I can't remember the value...27 to 40 ohms full and 240 to 260 empty, or something like that. Hopefully somebody knows. I do know the value then changed later on by moco and the value may be different based on model but don't know for sure. YD
6th Gear
Joined: Dec 2011
Posts: 12
Likes: 0
From: Hudson, Florida
This is an old post, but folks might still be interested in it.
Basically, to test to see if it is the sender, gauge or wiring do this.
There is a quick connect plug that goes from your sender to your gauge. You need to remove the cover from the top of your tank to get to it. There are 2 wires.
With the key on, jump the 2 wires that to go to the sending unit together. The fuel gauge should then read full.,it may take a bit of time for it go to full. If it does not, then you have a bad ground to the sender, a bad gauge or bad wire.
If your gauge reads full all the time, then disconnect the quick connect to your sender. The gauge should go to empty. If it stays on full, then the 2 wires going to the sender are shorted together or the non-black wire is shorted to ground or your sender is stuck in the full position.
Basically, the fuel gauge is a volt meter. There is a rheostat in the sender. The black wire going to the sender is always to ground. The white wire is the return of the ground to the gauge. As the sender float rises, it reduces the resistance to ground which causes your fuel gauge to move towards full.
Assuming that your gauge does not move when you try the above, then your sender could be bad. Remove it from the tank being careful if there is any gas in it.
with the sender removed, with the key on, manually move the float lever up and down and see if the fuel gauge moves. There may be a delay being moving the float lever and the gauge moving. So, be patient. If it does not move and the gauge does go to full when you jump the 2 wires together, then your sender is bad. If it does move, it might have just been frozen or had some crud on it. Try to clean it and then try again.
In my case, I had not run my bike for 5 years and the sender got all gummed up. I tried to clean it and it still did not work and I had to replace the sender.
Good luck.
Basically, to test to see if it is the sender, gauge or wiring do this.
There is a quick connect plug that goes from your sender to your gauge. You need to remove the cover from the top of your tank to get to it. There are 2 wires.
With the key on, jump the 2 wires that to go to the sending unit together. The fuel gauge should then read full.,it may take a bit of time for it go to full. If it does not, then you have a bad ground to the sender, a bad gauge or bad wire.
If your gauge reads full all the time, then disconnect the quick connect to your sender. The gauge should go to empty. If it stays on full, then the 2 wires going to the sender are shorted together or the non-black wire is shorted to ground or your sender is stuck in the full position.
Basically, the fuel gauge is a volt meter. There is a rheostat in the sender. The black wire going to the sender is always to ground. The white wire is the return of the ground to the gauge. As the sender float rises, it reduces the resistance to ground which causes your fuel gauge to move towards full.
Assuming that your gauge does not move when you try the above, then your sender could be bad. Remove it from the tank being careful if there is any gas in it.
with the sender removed, with the key on, manually move the float lever up and down and see if the fuel gauge moves. There may be a delay being moving the float lever and the gauge moving. So, be patient. If it does not move and the gauge does go to full when you jump the 2 wires together, then your sender is bad. If it does move, it might have just been frozen or had some crud on it. Try to clean it and then try again.
In my case, I had not run my bike for 5 years and the sender got all gummed up. I tried to clean it and it still did not work and I had to replace the sender.
Good luck.
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Thread Starter
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Tourer
Joined: Aug 2014
Posts: 302
Likes: 49
From: Gambrill, MD
Oddly enough, my gauge start to work (sort of) after I put the bike together after replacing the inner faring (which required all the wiring to be removed from the radio, dash switches, gauges, etc.) and doing a top end gasket replacement (which required removal of the tank). So, I don't really know what the problem was. Having said that, the gauged only indicates about 3/4 full when the tank is completely full. I haven't bothered to do any measurements to figure out what that's the case.
-Dave
-Dave
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