Sylvie Willis
Removing the fuel gauge from the tank of a Harley-Davidson motorcycle can be a straightforward process, but it requires careful attention to avoid damage or injury. Before beginning, it is recommended to consult the service manual for specific instructions and diagrams. The first step is to disconnect the fuel gauge wiring harness and any relevant electrical connectors. Then, one must locate and unplug the wires connected to the fuel gauge, taking note of the wire colours and their orientation. After this, the fuel gauge can be lifted out of the tank, and the wires pulled through. When reinstalling, it is crucial to ensure the wires are correctly fed through the tank and plugged in before securing the gauge in place.
Removing a Harley Fuel Gauge from the Tank
| Characteristics | Values |
|---|---|
| Difficulty | Straightforward |
| Tools | Electrical pick, funnel, hose, catch can/gas can, vice-grips, screwdriver |
| Precautions | Avoid using steel tools to prevent sparks |
| Steps | 1. Disconnect fuel line and drain tank. 2. Disconnect wiring harness. 3. Remove mounting bolts. 4. Disconnect connector and remove pins. 5. Pull up on fuel gauge, pulling wires through tube. |
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What You'll Learn
Locating the wiring harness
First, it is important to understand the basic procedure for fuel gauge removal. The wires from the fuel gauge typically run through a special tube and exit at the bottom of the tank. They then connect to a small connector located near the tank. To access this connector, you may need to remove the mounting bolts and slightly lift the tank.
Now, let's focus on locating the wiring harness:
- Start by identifying the correct tools for the job. A service manual specific to your Harley-Davidson model can be extremely helpful and provide detailed diagrams and instructions. Additionally, having the right tools, such as a small electrical pick or a jeweller's screwdriver, can make the process safer and more efficient.
- Begin the process by locating the fuel gauge wires. On some Harley models, such as the Softail, you will find a clip with wires on the left side of the bike, near the plugs. Unhook the wires from this clip.
- Follow the wires: Carefully trace the wires downward from the clip. They should lead you directly to the wiring harness, which is typically located under the left side of the tank.
- Accessing the wiring harness: To access the wiring harness, you may need to remove the fuel tank console and gauge cluster assembly. This will involve removing screws and bolts, and it is important to keep the hardware organised for reassembly. Be cautious when working with an empty fuel tank, as it may still contain fuel fumes, and any sparks could be dangerous.
- Exposing the connector: With the tank slightly lifted or the console assembly removed, you should now be able to see the connector and wiring harness more clearly. The connector typically has four pins but only uses three wires. The wires correspond to specific functions: orange for +12V, black for ground, and yellow for the gas gauge signal.
- Diagram for reference: Before proceeding, it is highly recommended to create a simple diagram showing which wire goes into which hole of the connector. This will be invaluable during the reassembly process.
By following these steps, you should now have successfully located the wiring harness and be ready to proceed with the next steps of removing the fuel gauge from your Harley-Davidson fuel tank. Remember to work carefully and refer to your service manual for model-specific details.
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Disconnecting the connector
The first step is to identify the connector. The wires from the gauge go down through the tank via a special "tube" and exit the bottom of the tank. The wires then connect to a small connector near the tank. You may need to remove the mounting bolts and lift the tank slightly to see the connector. It is a 4-pin connector, but only 3 wires are in use. Before disconnecting, make a diagram showing which wire goes into which hole, and note the colours and holes based on the connector clip location. The orange wire is +12V, the black is ground, and the yellow wire sends the signal for the gas gauge function.
Once you have identified the wires, disconnect the connector. You will need to remove the pins from the connector. You can use a small electrical pick or a jeweller's screwdriver to do this. Be careful not to damage the pins, as this will render them unusable. Once the connector is disconnected, you can simply pull the gauge up, pulling the wires through the tube.
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Removing the fuel tank
Step 1: Drain the Fuel Tank
Before starting, it is recommended to ride the bike until it is low on fuel. Using a funnel, hose, and suitable catch can/gas can, disconnect the crossover fuel line at the front of the tank. Pinch the disconnected side of the line to prevent spills, and let the fuel drain into a gas can.
Step 2: Disconnect the Fuel Gauge
The fuel gauge wiring harness will need to be disconnected. First, locate the wiring harness by finding a clip with wires on the left side of the bike, under the tank. Unhook the wires from the clip and follow them until you find a plug. Disconnect the plug, and gently lift the fuel gauge out. Take note of the wiring order: the orange wire is +12V, the black wire is ground, and the yellow wire sends the signal for the gas gauge function.
Step 3: Remove the Tank Console
Remove the tank trim screws, if applicable, and then the console screws. Lift the console assembly upwards to access the gauge cluster wiring harness connections and disconnect them.
Step 4: Disconnect the Fuel Vent Line
Disconnect the fuel vent line from the vapor valve on the underside of the tank.
Step 5: Remove the Fuel Tank
With the fuel drained and all connections disconnected, the tank can now be safely removed and set aside. Be cautious when handling the fuel tank, as even an empty tank will contain fuel fumes, and using steel tools carelessly can create a spark.
Reinstalling the fuel tank can be accomplished by following the reverse procedure of tank removal. Ensure all connections are secure and properly engaged to prevent fuel leaks.
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Reattaching the fuel gauge
To reattach the fuel gauge, follow these steps:
First, ensure that the fuel system pressure is relieved and the battery is disconnected. This is important to prevent the possibility of high-pressure fuel spray and accidental shorts, which could lead to potential fire hazards. Now, reconnect the fuel gauge wiring harness, paying close attention to the order and orientation of the wires. The orange wire is +12V, the black wire is ground, and the yellow wire sends the signal for the gas gauge function. Secure the wires in the correct direction and plug them into the factory plug. Push the gauge into position, being careful not to twist it.
Next, reattach the fuel vent line to the vapor valve, ensuring that the valve is in a vertical position for proper venting of fuel vapors. Install the tank console and gauge cluster assembly, connecting all electrical harnesses before securing the console and tank trim to the fuel tank.
Then, connect the fuel crossover line, using a new length of fuel line if necessary. Be sure that the quick-connect fitting properly engages to prevent fuel leaks. Reconnect the battery and install the seat unit.
Finally, fill the tank with fuel and check for leaks. You may also want to test the gauge by slowly moving the float from full to empty to ensure it is functioning correctly. If you notice any issues, such as a sticky float or a broken ground wire, address them accordingly.
It is important to take your time and follow the steps carefully to ensure a successful reattachment of the fuel gauge and the proper functioning of your Harley-Davidson motorcycle.
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Safety precautions
To remove a Harley fuel gauge from the tank, there are several safety precautions one should take to ensure the process is completed correctly and without causing damage to the vehicle. Here are some detailed instructions to follow:
Firstly, it is important to understand the wiring of the fuel gauge. There are typically three wires within the plug: an orange wire (+12V), a black wire (ground), and a yellow wire (sends a signal for the gas gauge function). Make sure to note the order and orientation of these wires before proceeding. The wrong style or size of electrical pick can damage the pins, so refer to your service manual if you are unsure.
When removing the wires, take care to pull them gently through their solid tube or channel within the tank. If you encounter significant resistance or feel like you need to pull hard on the harness, stop and reassess. You may need to stagger the pins to pull them through safely.
If you are replacing the stock gauge with an aftermarket gauge, use the same factory plugs and pin connectors. If the new gauge does not come with the correct pins, they can usually be purchased from a local dealer. Ensure that you do not cut corners during the removal or installation process. The final result should look like the gauge was installed at the factory.
Additionally, make sure there is enough slack in the wires to lift out the gauge. At the bottom left side of the fuel tank, gently bend back the flexible clip to free the fuel gauge conduit. If needed, open the harness clamp on the frame to release the conduit. Pull on the conduit to remove the Multilock connector. Refer to the appropriate service manual for specific instructions on your Harley model.
By following these safety precautions and carefully studying the wiring and connections, you can successfully remove the Harley fuel gauge from the tank without causing any damage to the vehicle.
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Frequently asked questions
Removing the fuel tank from your Harley may seem difficult, but the process is quite simple. Here are the steps you should follow:
- Disconnect the fuel vent line from the vapor valve on the underside of the tank.
- Remove the front and rear tank mounting bolts.
- Lift the tank and set it aside.
- Disconnect the fuel gauge wiring harness.
- Remove the tank console and gauge cluster assembly.
- To remove the fuel gauge, disconnect the wires and lift it out.
It is recommended to ride the bike until it is low on fuel before removing the tank. Here are the steps to remove the fuel tank:
- Using a funnel, hose, and gas can, disconnect the crossover fuel line at the front of the tank.
- Pinch the disconnected side of the line to prevent spills, and let the fuel drain into the gas can.
- Remove the tank trim screws, console screws, and lift the console assembly upwards.
- Disconnect the gauge cluster wiring harness connections and the fuel pump module connector.
- Remove the front and rear tank mounting bolts and washers.
- The tank can now be removed and set aside.
To disconnect the wires from the fuel gauge, follow these steps:
- Note the order and orientation of the wires 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.
- Use a small electrical pick to remove the wires from the plug.
- Pull the wires through the solid tube/channel within the tank.
- Disconnect the connector near the bottom of the tank and remove the pins from the connector.
Yes, it is important to take some safety precautions when removing the fuel gauge from your Harley tank. Here are a few tips:
- Be careful not to pull too hard on the wires or harness to avoid damage.
- When removing the sending unit, use caution as even an empty fuel tank will contain fuel fumes. Avoid using steel tools carelessly as they can create sparks, which can be dangerous.
