Fuel gauge reads low 2005
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Road Warrior
Joined: Feb 2012
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From: Florida
Fuel gauge reads low 2005
Bike sat for years, replaced all of the internals in the tank, including sending unit. The fuel gauge now reads low, and will trip the light while theres still 1.5-2 gallons in the tank. I know the gauge is resistance based, is there a known bottleneck connector that could be the culprit?
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,160
Likes: 11,249
From: San Diego, CA
Bike sat for years, replaced all of the internals in the tank, including sending unit. The fuel gauge now reads low, and will trip the light while theres still 1.5-2 gallons in the tank. I know the gauge is resistance based, is there a known bottleneck connector that could be the culprit?
Is it carb or EFI.....By "replaced all of the internals in the tank, including sending unit" sounds like we are talking EFI, but you don't say for sure... Even the carb bikes have (internals) and a sending unit in the tank....
Anyways, if you removed the tank for the internal parts repair, there is a connector on the left side (primary side) of the tank, along the top frame backbone. The fuel gauge wires run through a tube in the tank, out the bottom at the left front, and connect to the bike's harness at the above mentioned connector....Those connector pins can get bent, leading to improper contact and cause a bunch of fuel gauge issues. I found that out the hard way...
If that connector was handled (removed, pushed, pulled, or prodded) during the replacement of tank internals, I'd check that connector first... it's free.
The only other thing that pops into my mind, is both Carb & EFI sending units have a float, at the end of an arm. As it moves up & down with the fuel level, it sends signals to the gauge on the tank volume. If the gauge is working properly, except for it is not accurately and consistently reporting low volume, that float arm may have been bent during installation.
Good luck with your diagnosis and keep us posted
Tourer
Joined: Aug 2019
Posts: 380
Likes: 153
From: Hot Springs, SD
I upgraded the speedo on my 05' to a speedo/tach combo that has a fuel gauge there as well as the one on the tank cap. The cap gauge is accurate but the gauge tach always shows 1/8 of a tank low. It irritated me so I just turned off the speedo gauge and use the cap one in combination with the odometer.
Seasoned HDF Member
Joined: May 2005
Posts: 10,232
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From: Georgia
I haven’t had a fuel gauge since a month after I bought my 05 Train. After several trials I ended up using trip meter at fill up with stock motor at 160 miles and never ran out of gas. Close enough for me.Bigger motor now I fill at 150 miles. I very rarely run thru a tank steady riding.
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,160
Likes: 11,249
From: San Diego, CA
I upgraded the speedo on my 05' to a speedo/tach combo that has a fuel gauge there as well as the one on the tank cap. The cap gauge is accurate but the gauge tach always shows 1/8 of a tank low. It irritated me so I just turned off the speedo gauge and use the cap one in combination with the odometer.
I never owned one of those Speedo/Tach combos. It could very well be my old man memory, but I thought I read once there was a calibration procedure for the fuel gauge portion.... If you still have the install instructions, you may want to give them a quick scan...
If my memory is wrong on that... sorry for wasting your time
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Road Warrior
Joined: Feb 2012
Posts: 1,719
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From: Florida
Well, I sold the bike before fixing the problem. I explained to the new owner about the plug that Hattitude mentioned, but I'm not sure he really got it or not. He's over three hours away, rode the bike home, so I won't be able to help him fix it.
Seasoned HDF Member
Joined: Nov 2004
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From: Ottawa, CANADA
I had a similar issue with Reaper (2005 Night Train). I fixed it by bending the floater arm, that hangs off the sending unit, until it read correctly. Even then, I still use my Trip B odometer as my fuel gauge, and fill up around 180 - 190 miles (if I'm running steady highway speed).
Cheers!
Cheers!
Last edited by Clammy; Mar 27, 2024 at 08:43 AM.
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Supporter
Joined: Sep 2006
Posts: 3,714
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From: San Ramon, Ca
My 03 has read low since day one. When it's close to the E and the low fuel light
comes on, it will take 3.5 gal (aprox)
I also use my trip meter every time I fill up. I figure on 35 mpg, so I usually fuel
at 140 mi.
comes on, it will take 3.5 gal (aprox)
I also use my trip meter every time I fill up. I figure on 35 mpg, so I usually fuel
at 140 mi.
Tourer
Joined: Aug 2019
Posts: 380
Likes: 153
From: Hot Springs, SD
I never owned one of those Speedo/Tach combos. It could very well be my old man memory, but I thought I read once there was a calibration procedure for the fuel gauge portion.... If you still have the install instructions, you may want to give them a quick scan...
If my memory is wrong on that... sorry for wasting your time
If my memory is wrong on that... sorry for wasting your time
It does have a cal section, I did it twice and came up with the same thing. According to HD this combo gauge may not have all functions active on an 05' and the ones it does have (except for speedo/odo) may not be accurate. I believe it was designed to work with 06' and up Touring bikes. I didn't have much choice as my speedo was bad and they no longer made it's direct replacement except for the combo gauge. Such is life with an older bike.