Rajan Wilcox
Many motorcycles do not come with a fuel gauge, but there are ways to add one to your fuel tank. One way is to drill a hole at the top of the tank and another at the bottom, connecting the two with a clear tube. This allows you to see the fuel level at all times. Another method is to use a fuel sight gauge, which can be installed on the side of the gas tank. This method requires welding and should only be attempted if the tank has been thoroughly cleaned to avoid any accidents. There are also universal fuel gauges that use a level sensor to measure the fuel level without needing a float in the fuel tank. These gauges can be calibrated to the shape of the fuel tank and display the real amount of fuel remaining.
| Characteristics | Values |
|---|---|
| Installation | Drilling two holes at the top and bottom of the tank and connecting them with a clear tube |
| Trip Odometer | Resetting the trip odometer after filling up the tank to know the number of miles left before needing to switch to the reserve |
| Reserve Switch | All bikes without fuel gauges have a reserve switch, usually about 1 gallon |
| Sight Gauge | A sight gauge can be installed into the side of the gas tank to see when the motorcycle is running low on gas |
| Sight Glass Bungs | Bungs are used to weld the sight gauge to the gas tank, with sealant used on the threads to prevent leaks |
| FuelGaugePro | A universal float-free motorcycle fuel gauge that uses a level sensor to measure the fuel level without needing a float in the fuel tank |
| Brass Sight Glass | A type of external fuel gauge that is shatter-resistant and temperature-resistant from -40°F to 180°F |
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What You'll Learn
Drilling holes at the top and bottom of the tank to connect with a clear tube
Firstly, you will need to drill two holes in your fuel tank, one at the top and one at the bottom. This will allow you to visually check the fuel level in the tank by seeing how high the fuel rises in the tube. You can mark the tube with a Sharpie to indicate levels such as half full or a quarter full.
Next, you will need to source a clear fuel hose or tube that is long enough to connect the two holes. You will need to feed the tube through the holes so that it is on the inside of the tank. This is where you will need to be creative in finding a way to seal the tube gas-tight where it enters the tank.
Once the tube is in place, you will be able to see the fuel level at all times. This method is a simple and cost-effective solution, but it is important to note that it may devalue your motorcycle and some may consider it unsafe due to the holes in the tank.
If you are happy with the potential drawbacks, this method of drilling holes and connecting a clear tube is a straightforward way to add a fuel gauge to your motorcycle without the need for complicated digital gauges or aftermarket solutions.
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Using a trip meter to calculate MPG at each fill-up
Many motorcycles do not have a fuel gauge, and instead, only have a low-fuel light that comes on when there is about 20% capacity remaining. This is where a trip meter comes in handy.
Using a trip meter to calculate your MPG at each fill-up is a straightforward process. First, you need to fill up your motorcycle's fuel tank. Make sure you fill it to the same point every time, on level ground, and on the same central or side stand. Then, reset the trip meter to zero. Take a short ride, ensuring that you ride as you usually would and that you use at least half of the fuel in the tank.
Next, record the distance you have travelled by reading the trip meter. If you are using the master odometer, subtract the new reading from the original reading to get the distance travelled. Now, calculate your MPG by dividing the miles travelled by the amount of fuel consumed. For example, if you have ridden for 124 miles and used 2.5 gallons of fuel, your calculation will be 124/2.5 = 49.6 mpg.
By calculating your MPG at each fill-up, you can get a running total of the miles travelled on the tank. This will help you predict when you will need to refuel and estimate the cost of a trip, ensuring that you are not left stranded without fuel.
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Using a fuel gauge kit with shatter-resistant glass
A fuel gauge kit with shatter-resistant glass can be a useful addition to your motorcycle, especially if you have a small gas tank. This guide will take you through the process of installing a fuel gauge kit with shatter-resistant glass on your motorcycle's fuel tank.
First, you need to acquire a suitable fuel gauge kit. There are various options available on the market, such as the ones offered by Amazon and Billetproof Design, which include brass sight glass-style external fuel gauges with shatter-resistant glass. These gauges are designed to be welded into the side of your gas tank, allowing you to easily monitor your fuel level.
Once you have purchased your fuel gauge kit, you need to prepare your motorcycle's fuel tank for installation. Ensure that the tank is thoroughly cleaned and free of any oil or dirt, as this will help ensure a proper weld.
Next, you can begin the installation process. Carefully weld the bungs provided in the kit to the fuel tank, following the manufacturer's instructions. The bungs should be welded securely, but be cautious not to overdo it with the heat to avoid distorting the threads.
After welding, you can install the sight gauge. Thread the elbow fittings into the bungs, using thread sealant for a secure fit. The angle of the fittings can be adjusted to achieve your desired look, whether it's a straight, curved, or S-shaped sight gauge.
Finally, test your new fuel gauge to ensure it is functioning properly. With your new fuel gauge installed, you can now easily monitor your fuel level while riding, giving you peace of mind and helping you avoid running out of gas.
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Using a level sensor to measure fuel level without a float
There are several ways to measure the fuel level in a motorcycle without using a float. One method is to use a hydrostatic pressure fuel gauge, which is a float-free fuel gauge that measures the fuel level based on the fuel's hydrostatic pressure. This type of gauge has a sensor under the fuel tank with two ports: an inlet and an outlet. The inlet port is connected to the fuel tank hose, and the sensor measures the fuel's hydrostatic pressure and sends this information to a microcomputer that evaluates the data and displays the fuel level. This type of gauge can be easily connected without making any modifications to the fuel tank.
Another way to measure fuel level without a float is to use a liquid dipstick. This involves inserting a dipstick into the fuel tank to measure the fuel level. A flashlight can also be used to peek into the tank and estimate the percentage of fullness. For example, if you know your tank capacity and can see that it is half full, you can calculate the approximate number of gallons of fuel remaining.
Additionally, you can calculate your motorcycle's fuel level by tracking mileage and fuel consumption. By knowing your motorcycle's fuel tank capacity and average miles per gallon, you can estimate how much fuel is left in the tank based on the number of miles ridden. This can be done manually or with the help of a mileage-tracking phone application.
Finally, you can install an electric fuel gauge that uses a needle to indicate the fuel level on a scale from empty to full. This method requires installing a fuel hose kit into the motorcycle's fuel tank.
It is worth noting that some motorcycles may have unusual fuel tank designs and shapes, making it challenging to accurately measure the fuel level without a float. In such cases, a combination of the methods mentioned above can be used to estimate the fuel level more precisely.
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Cleaning the tank and bungs before welding
Before welding a fuel gauge glass to your motorcycle's fuel tank, it is important to clean the tank and bungs thoroughly to avoid gas vapors and the risk of an explosion. Here is a step-by-step guide to help you through the process:
Step 1: Drain the Tank
Start by draining all the gas from the tank. This is a crucial first step to ensure that no flammable liquids are present during the welding process.
Step 2: Remove Gas Residue
Next, you need to remove any remaining gas residue. Wash the tank and bungs multiple times with soapy water or a detergent, such as Castrol Superclean. Rinse thoroughly, making sure to remove all soap or detergent residue.
Step 3: Evaporation
After rinsing, let the tank sit outside for a few days to allow any remaining liquids to evaporate. This step is important for safety, as it reduces the risk of flammable vapors being present during welding.
Step 4: Drying and Final Rinse
Once the tank is dry, you can rinse it with a small amount of gas, coating all surfaces. This final rinse helps prepare the tank for welding by creating an inert environment.
Step 5: Welding Preparation
Before welding, ensure that the tank and bungs are free of any oil or dirt. Use a clean rag or shop vac to wipe down all surfaces, ensuring they are ready for the welding process.
Remember, always exercise extreme caution when working with flammable liquids and welding. It is crucial to take the necessary time and precautions to ensure a safe working environment.
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