How do you install a fuel gauge on a 2004 H-D fatboy

https://www.youtube.com/watch?v=M65rN9fm_nQ

If the LED fuel gauge does not have connectors to match the factory connectors, then you need to take this to a qualified tech or return the product. See the diagram for connection points. "Brand X" electrical products are challenging to install.

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.

Go back to H-D and ask parts to print you off the instructions. Some bikes need an adapter also.

sounds like you may have the wrong gauge for the sender or a sender unit wrong for the gauge ,take it back to the dealer and get them to sort it out cheers

The right side cap comes off so you can add fuel. The crossover hose at the front of the tank lets fuel flow to both sides. The left cap holds the fuel gauge and fits into a hollow hole. The fuel gauge wiring comes out at the bottom of the tank, thru this hole. Don't try to twist the left cap off or you could damage the wiring for the gauge!

If the fuel gauge is in the tank where the left side fuel cap should be, rock the fuel gauge while pulling up on it. It's held in by an O-ring. Be careful as the wires that run from the gauge to the sending unit in the tank are very short.

If you need information about how the fuel gauge works and testing, contact me off forum at [email protected] I'll send you some information on it. This forum will only allow me to attach a file of 150kb. Much to small to be of much good. Remind me of what you need.

Good Luck
Steve

Fuel Filter Removal & Installation To Remove:

1. Remove fuel tank unit beneath floor access panel.
2. Remove fuel filter from fuel pump/fuel gauge sending unit.

To Install:

1. Install fuel filter to fuel pump/fuel gauge sending unit.
2. Install fuel tank unit and floor access panel.

It is in the fuel tank....here is the directions on how to do the job:

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Relieve the fuel system pressure.
   
3. Disconnect the negative battery cable.
   
4. Remove the rear seat cushion from the vehicle.
   
5. Clean any dirt that has accumulated around the fuel pump cover so it will not enter the tank during pump removal and installation.
   
6. Remove the fuel pump cover.
   
7. Disconnect the fuel gauge connector, hoses, and the gauge.
   
8. Disconnect the fuel pump electrical connector.
   
9. Remove the fuel pump from the bracket assembly.
   
10. Remove the seal ring and discard.
    

To install:

1. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
   
2. Apply a light coating of grease on a new seal ring to hold it in place during assembly.
   
3. Install the seal ring.
   
4. Install the fuel pump to the bracket assembly carefully to ensure the filter is not damaged. Be sure the seal ring remains in the groove.
   
5. Hold the pump assembly in place, and pull the fuel pump down so that it is tight against the bracket.
   
6. Connect the fuel pump electrical connector.
   
7. Connect the fuel gauge, hoses, and gauge connector.
   
8. Install the fuel pump cover.
   
9. Install the rear seat cushion.
   
10. Connect the negative battery cable.
    
11. Start the engine and check for proper system operation and for fuel leaks.
    

The FOB is a security device that will help protect your bike. If it is far enough away (i think 20 feet) your bike will not start, Without the FOB the fuel pump will not run and the lights will flash on and off. When you come back to the bike with the FOB the bike will run normaly. So do not leave it with the bike unless you want it gone when you come back.