Discussion:
HD 2002 Low Rider Fuel Gauge and Wiring Problem
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Manjo
2012-08-07 15:12:58 UTC
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The gauge is as old as the bike.
There's power to the gauge's black and orange wires.

I pulled out the fuel gauge and found the black ground wire going into the back of gauge was too short to allow the gauge to come out all the way.
But I did find that the orange +12 VDC wire that runs along with the black ground wire through the gas tank was broken right at the bottom of the gauge tank cup receptacle leaving no wire stub with nothing to work with to splice in an extension.

Looking at the bottom of the gauge itself, it appears that the wires go into the housing and are attach to the printed circuit board out of sight.

I have two questions:
1. Are the three wires (orange, black, and yellow/white) soldered directly to the printed circuit board in the gauge housing? If so, is there a way to open the housing without breaking it to replace or at least have a bit more room to splice-in a length of wire on each?

2. Do the black and orange wires at the bottom of the fuel tank's gauge receptacle providing 12+ volts and ground to the gauge feed through the gas tank in any kind metal tubing? Or do the wires that enter the gas tank at the bottom and run up to the gauge receptacle sit exposed in the gas tank?

The only thing I can figure out is that I might have a bad fuel gauge, but it's certain I have to run a new pair of black and orange electrical power wires up through the gas tank for the fuel gauge.

Thanks in advance for any fixes, tips, suggestions on fixing the fuel gauge.

Manjo 2002 LowRider
Graduated Cylinder
2012-08-07 18:44:22 UTC
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The gauge is as old as the bike. There's power to the gauge's black and orange
wires.
I pulled out the fuel gauge and found the black ground wire going into the back of
gauge was too short to allow the gauge to come out all the way. But I did find
that the orange +12 VDC wire that runs along with the black ground wire through
the gas tank was broken right at the bottom of the gauge tank cup receptacle
leaving no wire stub with nothing to work with to splice in an extension.
Looking at the bottom of the gauge itself, it appears that the wires go into the
housing and are attach to the printed circuit board out of sight.
I have two questions: 1. Are the three wires (orange, black, and yellow/white)
soldered directly to the printed circuit board in the gauge housing? If so, is
there a way to open the housing without breaking it to replace or at least have a
bit more room to splice-in a length of wire on each?
2. Do the black and orange wires at the bottom of the fuel tank's gauge receptacle
providing 12+ volts and ground to the gauge feed through the gas tank in any kind
metal tubing? Or do the wires that enter the gas tank at the bottom and run up to
the gauge receptacle sit exposed in the gas tank?
The only thing I can figure out is that I might have a bad fuel gauge, but it's
certain I have to run a new pair of black and orange electrical power wires up
through the gas tank for the fuel gauge.
Thanks in advance for any fixes, tips, suggestions on fixing the fuel gauge.
Manjo 2002 LowRider
Can't answer either 1. or 2., but these two pages

<http://www.hdtalking.com/softail_models/25613-2005_flstni_fuel_gauge_removal.html>

<http://www.hdforums.com/forum/dyna-glide-models/687505-fuel-gauge-wiring-confusing-2.html#post8824367>

suggest that you need to release the connector from the wires where they come through
the bottom of the tank, then you can pull the wires through from the top.
Manjo
2012-08-07 20:41:22 UTC
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SNIP<
Can't answer either 1. or 2., but these two pages <http://www.hdtalking.com/softail_models/25613-2005_flstni_fuel_gauge_removal.html> <http://www.hdforums.com/forum/dyna-glide-models/687505-fuel-gauge-wiring-confusing-2.html#post8824367> suggest that you need to release the connector from the wires where they come through the bottom of the tank, then you can pull the wires through from the top.

Very helpful.
I did hace a gasoline leak at the bottom of the tank at the point where the blk and orange wires entered the tank. I sealed-ff the leak with GOOP and it's heldfor quite some time. It will be easy to release the GOOP and the connector pins after I drain the tank.

thanks for the reply.

Manjo

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