Question about 2004 Harley Davidson FLSTC - FLSTCI Heritage Softail Classic

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2004 fatboy fuel gauge reads full all the time. where is the ground for the sending unit?

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The fuel gauge is really two parts. You have a guage and a sending unit. You must have voltage going to the unit as well. On most models, the wires that supply voltage to the gauge run upwards through a small tube in the tank for the bottom of the tank. There is a connector at the bottom of the tank in most cases.

Using a VOM (volt/ohm meter) unplug the connector beneath the tank and check for voltage with the ignition switch on. You should have approx. 12 volts. Once you've finished this test, turn the switch back to the off position.

Next, you will have to check the sending unit. Remove the gauge from it's rubber gasket that holds it in position on the tank. Carefully work the gauge up and out of the rubber sleeve because the wires are very short. Once you have the gauge out, you'll have to check the resistance of the sending unit with the tank nearly full and then again with the tank nearly empty. If the resistance of the sending unit changes, the problem is probably the gauge itself. If the resistance does not change, the problem is more than likely with the sending unit. Check the sending unit for a good ground as well.

The sending unit is held in the tank by five or six small screws. Remove these screws and lift the unit slightly. Do not attempt to remove the sending unit with the fuel tanks full and the bike on the side stand. Fuel will be all the way to the top of the tank and will spill out when you attempt to remove the sending unit. While lifting the unit, turn it working the float arm out of the tank. Be very careful not to bend the float arm. Once you have the unit out of the tank, you can check the unit's resistance again. When you remove the sending unit, always replace the gasket that goes beneath the unit.

Be very careful, you are working with gasoline and expolsive fumes. Do not smoke or have any open flames near.

Posted on Aug 02, 2010

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I have a problems with my gage on my 1997 ford Thunderbird the gas go to full all the time what could that be


Here are some suggestions:

TROUBLESHOOTING
PROBLEM: The fuel gauge does not work at all...no needle movement. With the ignition switch on, remove the wire from the fuel tank sending unit and ground it to the unit housing. This removes the resistance supplied by the sending unit, and should cause the gauge to swing over to the 'Full' position. Does this happen?
Yes
No
The gauge and wiring are good. The problem is most likely with the sending unit. The sending unit must be removed for further testing. (1) Ground the sending unit wiring to a good chassis ground (instead of the sending unit housing) and watch the gauge. Does it now peg out to the 'Full' side? Yes
No
The problem is with the sending unit ground. Either the unit itself is bad or the float/arm is binding/missing. The sending unit must be removed for further testing. The power supply to the gauge has been interrupted, (check fuses), the gauge is defective, or the wire from the gauge to the sending unit is open or has a break in it. Testing the Sending Unit After the sending unit has been removed from the tank, check to make sure the float is present, intact and still floats and that there is no binding with the float arm. Reconnect the gauge wiring to the unit and ground the unit. Move the float arm up and down. If the gauge reads full in the full up position and empty in the full down position, then the sending unit is good. Verify by hooking up an ohmmeter to it and making sure it reads 8-12 ohms full and 70-73 ohms empty. If not, the sending unit needs repaired or replaced. You can easily disassemble the head of the sending unit to clean and/or repair.

Apr 28, 2016 | Ford Cars & Trucks

2 Answers

2000 Dakota quad cab fuel gauge wont work, jumps to full when started, fuel pump has been replaced. What next?


Check for a frayed wire touching metal and grounding out. The gauge works on resistance and it registering full indicates a short to ground. Either that or your gauge itself is bad.

Sep 01, 2014 | 2000 Dodge Dakota Quad Cab

1 Answer

Why does the fuel light stay on


WHAT DTC\'s are set???



It sounds like a short to ground on the gauge circuit but see below for further and better diagnosis:



When the ignition switch is ON the fuel gauge is connected to 12 VDC, current flows through the gauge and the variable resistor in the fuel gauge sending unit to ground. The sending unit float controls the amount of resistance in the variable resistor. Malfunctioning fuel gauges may be the result of a fuel gauge sender or a fuel gauge not being properly grounded OR there may be a defect in the fuel gauge sender or in the fuel gauge itself OR there may be an open circuit caused by a loose or disconnected connection or a broken wire between the ignition switch to the fuel gauge.



A suspect fuel gauge system can be tested by FIRST removing the gauge and grounding the Y/W wire of the fuel gauge sender located at the bottom of the gauge, turning the ignition switch ON at which point the fuel gauge must indicate FULL. And if it does so then the fuel gauge is functioning correctly.And if it does not read FULL then get a multimeter set to the RX1 scale and measure the resistance of the sending unit by placing one of the meter probes on the Y/W wire and the other probe on a good ground. THEN for FLHT/C/U, FLTR if thefuel tank is full the meter reading should be 7-14 ohms and if the tank is empty the meter resistance reading should be 74-95 ohms resistance and a half full tank meter resistance reading will be approximately 30-38 ohms. For FLHR/C/S if the fuel tank is full, the meter resistance reading should be 27-40 ohms, if the tank is empty 240-264 ohms and if half full approximately 97-118 ohms. FOR ALL MODELS if there is a very high meter resistance or infinity reading the sender may be "open" or not grounded. In this case check to see if the sender and fuel tank are grounded by placing one of the ohmmeter probes on the flange of the sender and the other probe on crankcase and if the ground is good the meter must indicate one ohm or less and if the reading is one ohm or less the sender is defective and requires replacement and if a higher resistance reading is obtained you will need to check for a poor ground wire. THEN you can check the voltage to the O/W (+) wire and the BK (-) wire of the fuel gauge connector if the gauge did not indicate FULL and the correct reading will depend on the source voltage and the level of fuel in the tank or the position of the sender float arm on the variable resistor etc. If there is NO battery voltage present there may be a broken, highly corroded or disconnected power wire. If you cannot find a problem using the above testing replace the gauge itself.

May 29, 2014 | 2005 Harley Davidson FLHTCUI Electra Glide...

1 Answer

I have a 07 flhx and the fuel gauge reads full all time


When the ignition switch is ON the fuel gauge is connected to 12 VDC, current flows through the gauge and the variable resistor in the fuel gauge sending unit to ground. The sending unit float controls the amount of resistance in the variable resistor. Malfunctioning fuel gauges may be the result of a fuel gauge sender or a fuel gauge not being properly grounded OR there may be a defect in the fuel gauge sender or in the fuel gauge itself OR there may be an open circuit caused by a loose or disconnected connection or a broken wire between the ignition switch to the fuel gauge.



A suspect fuel gauge system can be tested by FIRST removing the gauge and grounding the Y/W wire of the fuel gauge sender located at the bottom of the gauge, turning the ignition switch ON at which point the fuel gauge must indicate FULL. And if it does so then the fuel gauge is functioning correctly.And if it does not read FULL then get a multimeter set to the RX1 scale and measure the resistance of the sending unit by placing one of the meter probes on the Y/W wire and the other probe on a good ground. THEN for FLHT/C/U, FLTR if thefuel tank is full the meter reading should be 7-14 ohms and if the tank is empty the meter resistance reading should be 74-95 ohms resistance and a half full tank meter resistance reading will be approximately 30-38 ohms. For FLHR/C/S if the fuel tank isfull, the meter resistance reading should be 27-40 ohms, if the tank is empty 240-264 ohms and if half full approximately 97-118 ohms. FOR ALL MODELS if there is a very highmeter resistance or infinity reading the sender may be "open" or not grounded. In this case check to see if the sender and fuel tank are grounded by placing one of the ohmmeter probes on the flange of the sender and the other probe on crankcase and if the ground is good the meter must indicate one ohm or less and if the reading is one ohm or less the sender is defective and requires replacement and if a higher resistance reading is obtained you will need to check for a poor ground wire. THENyou can check the voltage to the O/W (+) wire and the BK (-) wire of the fuel gauge connector if the gauge did not indicate FULL and the correct reading will depend on the source voltage and the level of fuel in the tank or the position of the sender float arm on the variable resistor etc. If there is NO battery voltage present there may be a broken, highly corroded or disconnected power wire. If you cannot find a problem using the above testingreplace the gauge itself.

May 10, 2014 | 2006 Harley Davidson FLHX Street Glide

1 Answer

I have a 2003 Fatboy fuel injected. I recently got the fuel gauge repaired. After leaving the dealer, I put 170 miles before the fuel light came on. I filled the tank to the top, and it only took 3.1...


Yes, your fuel gauge was not properly repaired in all likelihood. Take it back and advise them of this. ALSO:



When the ignition switch is ON the fuel gauge is connected to 12 VDC, current flows through the gauge and the variable resistor in the fuel gauge sending unit to ground. The sending unit float controls the amount of resistance in the variable resistor. Malfunctioning fuel gauges may be the result of a fuel gauge sender or a fuel gauge not being properly grounded OR there may be a defect in the fuel gauge sender or in the fuel gauge itself OR there may be an open circuit caused by a loose or disconnected connection or a broken wire between the ignition switch to the fuel gauge.



A suspect fuel gauge system can be tested by FIRST removing the gauge and grounding the Y/W wire of the fuel gauge sender located at the bottom of the gauge, turning the ignition switch ON at which point the fuel gauge must indicate FULL. And if it does so then the fuel gauge is functioning correctly.And if it does not read FULL then get a multimeter set to the RX1 scale and measure the resistance of the sending unit by placing one of the meter probes on the Y/W wire and the other probe on a good ground. THEN for Softail if the fuel tank is full, the reading should be 27-40 ohms. an empty tank should have a 240-264 ohm resistance and a half full tank will be approximately 97-118 ohms. FOR ALL MODELS if there is a very highmeter resistance or infinity reading the sender may be "open" or not grounded. In this case check to see if the sender and fuel tank are grounded by placing one of the ohmmeter probes on the flange of the sender and the other probe on crankcase and if the ground is good the meter must indicate one ohm or less and if the reading is one ohm or less the sender is defective and requires replacement and if a higher resistance reading is obtained you will need to check for a poor ground wire. THENyou can check the voltage to the O/W (+) wire and the BK (-) wire of the fuel gauge connector if the gauge did not indicate FULL and the correct reading will depend on the source voltage and the level of fuel in the tank or the position of the sender float arm on the variable resistor etc. If there is NO battery voltage present there may be a broken, highly corroded or disconnected power wire. If you cannot find a problem using the above testingreplace the gauge itself.

May 04, 2014 | 2003 Harley Davidson FLSTF Fat boy

1 Answer

My 2003 Fatboy's fuel light comes on, but the tank will only take about 2.5 to 3 gallons of fuel.


When the ignition switch is ON the fuel gauge is connected to 12 VDC, current flows through the gauge and the variable resistor in the fuel gauge sending unit to ground. The sending unit float controls the amount of resistance in the variable resistor. Malfunctioning fuel gauges may be the result of a fuel gauge sender or a fuel gauge not being properly grounded OR there may be a defect in the fuel gauge sender or in the fuel gauge itself OR there may be an open circuit caused by a loose or disconnected connection or a broken wire between the ignition switch to the fuel gauge.



A suspect fuel gauge system can be tested by FIRST removing the gauge and grounding the Y/W wire of the fuel gauge sender located at the bottom of the gauge, turning the ignition switch ON at which point the fuel gauge must indicate FULL. And if it does so then the fuel gauge is functioning correctly.And if it does not read FULL then get a multimeter set to the RX1 scale and measure the resistance of the sending unit by placing one of the meter probes on the Y/W wire and the other probe on a good ground. THEN for Softail if the fuel tank is full, the reading should be 27-40 ohms. an empty tank should have a 240-264 ohm resistance and a half full tank will be approximately 97-118 ohms. FOR ALL MODELS if there is a very highmeter resistance or infinity reading the sender may be "open" or not grounded. In this case check to see if the sender and fuel tank are grounded by placing one of the ohmmeter probes on the flange of the sender and the other probe on crankcase and if the ground is good the meter must indicate one ohm or less and if the reading is one ohm or less the sender is defective and requires replacement and if a higher resistance reading is obtained you will need to check for a poor ground wire. THENyou can check the voltage to the O/W (+) wire and the BK (-) wire of the fuel gauge connector if the gauge did not indicate FULL and the correct reading will depend on the source voltage and the level of fuel in the tank or the position of the sender float arm on the variable resistor etc. If there is NO battery voltage present there may be a broken, highly corroded or disconnected power wire. If you cannot find a problem using the above testing replace the gauge itself.

May 04, 2014 | 2003 Harley Davidson FLSTF Fat boy

1 Answer

I have a97 chevy c1500 the fuel gauge never worked,so i put a new sending unit in still dont work gauge reads past full @all times can anyone help


Your problem with you fuel gauge is not the sending unit or the gauge in the cluster. You have a broken ground wire in the the harness that goes to the sending unit. look for broken wires or wires that have bin picked with a test light they will have corrosion

Jan 26, 2014 | Chevrolet Cars & Trucks

1 Answer

70 c10 fuel gauge


You need to check voltage at the gauge on the dash.
They would stop at random places with the key off.
You can disconnect the sending unit in the tank and ground the gauge to test.
Some models read empty with high resistance from the sender, some are opposite depending on the sending unit. The sending unit in the tank is a resistance bar for the ground circuit.

Jul 03, 2012 | Cars & Trucks

1 Answer

Fuel gauge reads full all the time,and we did install a new sending unit with new fuel pump


Dont we wish it be full all the time but gas in it. Okay for the sending unit reading full its getting a full ground reading,Key on engine off. does it move and goe down. It should if it doesnt the problems with the gauge itself. 2 test disconnect the wire harness, did the gauge go down. the problem will be in the sending unit can be a hung float(Rare).

Apr 26, 2011 | 1994 Dodge Caravan

1 Answer

Fuel gauge problem


LOOK FOR A BROKEN GROUND WIRE. TOUCH WIRE FROM SENDING UNIT TO GROUND AND SEE IF GAUGE GOES TO EMPTY. IF IT DOSE THEN YOU'LL NEED TO REPAIR THE BROKEN GROUND WIRE TO SENDING UNIT.

Jan 20, 2010 | John Deere 420,1020,2010,2020,2510,2520...

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