Hi! I just bought a 1996 Electra Glide FLHTCUI. The bike runs well overall, but I’m working on fixing some minor issues. One problem is the fuel gauge. The needle jumps erratically. When I start the bike, instead of rising slowly to its range, it moves instantly. The same happens when I turn off the ignition, goes down instantly.

I replaced the fuel filter today (as I wasn’t sure if it has ever been changed) and gained access to the fuel sender. When I moved the sender up and down, the gauge responded instantly. I assume this isn’t normal and that it should move more gradually.

What do you think? Should I replace the sender, the gauge, or perform additional checks?

Thanks!

 

I am not an electrical guru....

But I believe the sending unit sends its signal in real time to the gauge, and it's the gauge that has a dampener built in, to stop erratic movement from the gas sloshing around in the tank.

So if I am remembering that correctly, I would think the dampener part of the gauge has failed. Not sure I'd bother replacing it though...

I only use my properly functioning fuel gauges as a reminder to check my trip odometer. I rely on the trip odometer to decide when I need to refuel.

Additionally, the gauges for your year/model are obsolete and unavailable from HD. They are in fact so far out of production, the HD OEM online service parts finder doesn't even show the OEM part numbers anymore. I suspect you'll need to invest in a '96 Touring bike parts catalog, to even find the correct OEM parts number(s), if you wanted to chase down new old stock or used on eBay..

I have no idea what may, or may not, be available on the aftermarket.

Hopefully someone with more electrical knowledge than me, or someone who has recently gone through an older EVO gauge replacement will chime in....

Good luck with your gauge replacement...

 

Thanks for the response, it’s a big help!

Yes, that’s exactly what I’m looking for: whether the “dampener” is in the sender unit or the gauge. As you said, I wouldn’t fully trust the gauge, the odometer is the way to go. But it’s annoying to see the needle jumping all over the place. It’s not critical, but I’d like to resolve the issue at some point.

I’ll start looking for any gauges on the market. Anyway, it would be great if someone could confirm whether that “dampener” is in the gauge or not.

 

I have held both a 2016 and 2003 fuel gauge sending unit in my hands. They both look like simple rheostats. I didn't see anything that would suggest a dampener circuit.... The check for a sending unit is to measure its Ohm range between its two end points... The ones I checked were both good, and the numbers changed immediately as I moved the float..

Since the OEM gauge seems to be hard to find, if you could get one reasonably priced, it might be worth getting it. Worst case scenario it wouldn't fix it, but you'd have a spare gauge...


NOTE: I just did some digging. It appears the #75111-96C Fuel Gauge fits '96-'07 Ultra bikes. There are a couple of used ones on eBay for around $80, and one NOS @ $125. Might be worth grabbing the new old stock one below;

https://www.ebay.com/itm/30642019143...CABEgJ9d_D_BwE

 

Hi!

Yep, I did some research and, as you said, that’s the part that fits my bike. And there are some units on the Internet, not as difficult to find as I thought.

Anyway, out of curiosity (and to avoid buying a gauge and then needing a sender), I’m trying to figure out how the fuel gauge system works. There must be something in the sender or gauge that stabilizes the needle so it doesn’t jump like crazy when the fuel moves around the tank. I haven’t checked the ohms of the sender (as my electrical skills are pretty limited xD), but yeah, when I move the float, the needle moves up and down instantly.

But it’s interesting that you mentioned the ohms of the sender change instantly. That reinforces the theory that something in the gauge must stabilize the readings.

 

My bet it’s the gauge itself. Your symptoms and simple test of the resistance on the sender and how it affected the gauge is what led me to purchasing a new gauge. Mine crapped out all herky jerky about fours years after new.

And yes I see them for your year on EBay and I think there was even an NOS fuel gauge for sale.

 

Needle dampener has failed. Pretty common issue on earlier 96+ fuel gauges. You need to find the latest revision 75111-96C. They were much more reliable and were installed up to model year 2006. I see some new on ebay for around $100

 

Thanks for your help!

So yes, I’m going to add the gauge to the to-do list (it’s still large xD), but glad to understand how the system works, I like to learn the maximum possible from the bike.

Thanks again to you all!