Gas gauge not reading to full its a 1/4 tank under. Bike is efi evo, any help would be great.

 

Fuel sender stuck?

 

My 1998 Ultra was doing the same thing for awhile....I let it continue that way, because it at least somewhat worked.

Then one day, all the guages died leaving only the speedometer and light to work. The guages fuse kept blowing.

The fuel sending unit was the culprit. The resistance on the fuel sending unit coil was not within spec.

Yours is probably just old and worn out.....our EVO bikes are aging.

 

How hard is it to change out the fuel unit?

 

It's a pain. Everything in the tank is hard to get to for some mystic reason. Also, the screws that hold the access panel on the top of the tank are some special seal bolts and I'm told aren't reuseable.

 

Moog player. Thanks. Also didn't I meet you last weekend.

 

I have a 99 classic and the fuel guage was not reading accurate since then the fuse blew out a couple of times and now a 20A will not last 10 sec. could tis be the same reasoning? I am goung to persue, but how much ohm should the sender have or will it dead short since it is blowing?

 

You can dead short the wire from the sender and not pop a fuse. You have other problems somewhere in the circuit.

 

Thanks for the reply. I started a few months ago, once in a while. today i was out on a ride and it started befor I left the house. I replaced it and pop again in 5 sec. I thought something is going bad a wire or a guage. I know the sender is going due to its lack of reading the fuel level accurate so I was going to replace it anyway. I need to fine a wire dia. to trace how the circuits go so I can trace this..

 

The fuel sending unit is actually very easy to replace. Unbolt the tank console and lay it to the side. Then remove all the screws holding the acess panel to the tank. The fuel sending unit is mounted to the acess panel. The sending unit comes out of the tank with the acess panel. You never even put your hands inside the tank!

People say and the manuals say that the acess panel screws are not reuseable. I've had the acess panel removed twice.....and always reusing the screws. I've never had to replace the acess panel cork type gasket either. I was always very careful not to tear it. No problems and no leaks!

Biggest thing.....before you reinstall the tank console. Make sure the fuel pump is working. The two connectors for the fuel pump are located on the acess panel and are easily bumped. It really sucks to do the job and have everything bolted down including the seat....and not hear the pump working! Don't ask me how I know??

One easy hour is enough time from start to finish.....