Replacing The Fuel Gauge On A 1993 H-D Wideglide

If you're looking to change the fuel gauge on your 1993 Harley-Davidson Wide Glide, you've come to the right place. This process can be done by carefully removing the old gauge and installing a new one. First, unplug the gas gauge from the main harness, taking note of the wiring order and orientation. Then, use a small electrical pick to remove the wires from their plug. Be cautious when pulling the wires through the tank, and if you encounter resistance, stop and reassess. When installing the new gauge, use the factory plugs and pin connectors, routing the wires back through the tank and securing them correctly. With careful attention to detail, your new fuel gauge will look like it was installed at the factory.

Harley-Davidson fuel gauge removal

• Repairing or replacing your fuel gauge
• Changing to an aftermarket gauge
• Getting your tank's paint repaired or relined

Fuel Gauge Removal Process

• Unplug the gas gauge from the main harness. Take note of the wiring order and orientation within the plug. The orange wire is +12V, the black is ground, and the yellow wire sends the signal for the gas gauge function.
• Use a small electrical pick to carefully remove the three wires from their plug. Refer to your service manual to ensure you use the correct pick, as the wrong size or style can damage the pins.
• Pull the wires through the solid tube/channel within the tank. You may need to stagger the pins and proceed with caution. If you feel a lot of resistance, stop and reassess, as something may be wrong.
• If you are installing an aftermarket gauge, use the same factory plugs and pin connectors. If the new gauge doesn't come with the correct pins, you can purchase them from a dealer.
• Reinstall the gauge by routing the wires back through the tank. Insert the wires into the factory plug, ensuring they are in the correct direction and order. Plug in the gauge and push it into position.

Additional Tips

• When adjusting or replacing the float arm, you can fabricate a special Harley service tool from a brazing rod to reach inside the tank and bend the float arm.
• If you are having issues with the fuel gauge connection, check the left, front side of the gas tank, as it may need to be reconnected.

Unplugging the gas gauge from the main harness

To unplug the gas gauge from the main harness of your 1993 H-D Wide-Glide, you will first need to take note of how the plug is wired. Identify the three wires and their orientation within the plug. The orange wire is +12V, the black wire is the ground, and the yellow wire sends the signal for the gas gauge function.

Using a small electrical pick, you can then remove the three wires from their plug. Be sure to reference your service manual to ensure you are using the correct pick as the wrong style or size can damage the pins and render them unusable.

Take care when pulling the wires through the solid tube or channel within the tank. If you feel resistance or have to pull hard on the harness, something is wrong. The wires should come through with little effort.

Ordering of the three wires and their orientation

When removing the fuel gauge, it is important to note the order of the three wires and their orientation within the plug. The orange wire is +12V, the black wire is ground, and the yellow wire sends the signal for the gas gauge function. A small electrical pick can be used to remove the wires from their plug. It is important to refer to the service manual to ensure the correct pick is used, as the wrong style or size can damage the pins.

When pulling the wires through the solid tube or channel within the tank, the pins may need to be staggered to ensure they are pulled through safely. If there is a lot of resistance, stop and reassess, as something may be wrong. The wires should be pulled through with minimal effort.

When installing a new gauge, the same factory plugs and pin connectors should be used. If the new gauge does not come with the correct pins, they can be purchased from a local dealer. The wires should be routed back through the tank, inserted into the factory plug, and secured in the correct direction and order. Finally, the gauge can be plugged in and pushed into position.

Using a small electrical pick to remove the wires from their plug

To remove wires from their plug, you will need a small electrical pick, such as a small flat-head screwdriver or a push-in connector release tool. These tools will help you safely remove the wires without causing any damage. It is important to work carefully and gently to avoid harm to the wires or connectors.

Begin by ensuring that the power to the circuit is shut off at the main breaker. This is a crucial step to prevent any risk of electrical shock. Verify that no electrical current is present by using a voltage tester. Safety should always be a priority when working with electrical systems.

Now, locate the push-in connector in your electrical setup. It may be hidden behind a cover plate or within an electrical box. Once you have located the connector, insert your small electrical pick into the release mechanism. Gently pry the wire loose, being careful not to apply too much force or pull at an angle, as this can damage the wire or connector.

Repeat this process for each wire that you need to remove from its plug. Remember to take your time and follow the steps carefully to avoid any mistakes. Working with electrical components can be tricky, but with the right tools, safety measures, and instructions, you can successfully remove the wires from their plugs.

Reattaching the gauge by routing the wires back through the tank

To reattach the fuel gauge, you must first correctly insert the wires back into the factory plug. The orange wire is +12V, the black is ground, and the yellow wire sends the signal for the gas gauge function. Secure the wires in the right direction and order, and plug in the gauge. Push the gauge into position, being careful not to cut corners. When the job is complete, it should look like the gauge was installed at the factory.

Frequently asked questions