My fuel gauge seemed to work fine for the first 1500 miles or so, since then i have had it in the shop twice to be adjusted or fixed and it seems like now it isn't working again. I always reset and keep a close eye on my miles but this is starting to **** me off that it hasn't been fixed. Has anyone else had a problem with the gauge? Pay good money for a bike so I expect all parts to work [:@]

 

I have a 05 Heritage and I have the same problem. I had it repaired several times and again its not working. I'm getting pissed.

 

I have issues with my fuel gauge on a 06 heritage classic. Seems to have 1/2 a tank of gas and the gauge reads 1/4 to 1/8. Also, a full tank only gets 170-180 miles which is well below 40+ miles per gallon. I'm taking it in for 1k mile checkup soon and have the dealer check it out.

 

04 softail haad the gage go dead they fixed the tank unit that lasted for awhile
same thing happened went back in had them order a new tank unit and so far it
is working fine all done under warrante

 

The gauge on my '02 Fat Boy suddenly stopped working last summer. Riding season is dead here, so I'll wait until spring before I go to Myrtle Beach and have it looked at. Starting with the simple stuff first, it doesn't seem to be a fuse issue.

 

The fuel guage is total crap ! mine has been in to the dealer twice but they have not managed to fix it yet. I recently bought the workshop manual for my bike and after looking at the way the guage works I decided to have a go and fix it myself.

If you remove the top chrome speedo cover you will find a plate which houses the fuel pump and guage sender etc. Remove all of the screws after you have unplugged the electrics and gently lift the cover slightly so that you can see into the tank. You will see the bracket holding the sender unit if you look from the right hand side of the tank. You need to gently bend it very slightly to the left hand side of the tank (Only a fraction) as the float jams against the tank when you fill it to the top with fuel.

I have filled the bike up 4 times now and the guage works perfectly, however they are not that accurate so bear in mind that the trip meter needs to be reset every time you fill up until you gain an idea as to how accurate the guage is. I never let the warning light come on as I fill it when it gets into the red.

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Its just the nature of the beast folks. HD uses a really cheap guages on their bikes. The float bowl assembly in the tank is pretty simple and relatively durable for what its supposed to do,and I have never encounted a "jammed" unit, but the circuit board on the guage is really really cheap and is prone to failure from stress cracks in the solder joints. I recommend going with an aftermarket guage and then putting some type of gasket material between the guage and the tank to help reduce the vibration that the circuitboard on the guage endures. Thats pretty much it in a nutshell.

 

I've heard of a few of these units hanging up the float and causing these problems. Here's a test proceedure to check out the fuel gauge https://www.hdforums.com/m_66687/tm.htm