Resolved: Boss Hoss Motorcycle Fuel Gauge Stuck on Full

repairs, maintanence, electrical wizardry, mechanical epiphany, etc.
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The Mindless Philosopher
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Joined: Mon Jul 04, 2016 3:24 pm

Resolved: Boss Hoss Motorcycle Fuel Gauge Stuck on Full

Post by The Mindless Philosopher »

How to correct a stuck analog fuel gauge:

Step 1: Disconnect the speedometer cable from the front wheel. If you cannot, skip to Step 2.

Note: I used a small Dremel tool to cut the screw threads off the speedometer cable sheath where it meets the speedometer sending unit's gear housing on the front wheel. I then cut a segment of fuel hose to act as a quick release/quick install system. If you do not have a quick release method, you will have to unscrew the collar from beneath the gauge cluster panel, as stated in Step 3a.

Step 2: Remove the top two screws beneath the gauges from the gauge cluster panel. The bottom two screws can remain in place, as they only connect the decorative chrome plates.

Step 3: Gently ease the gauge cluster housing up and back.

Step 3a: Turn the handlebar to provide slack for the speedometer cable and then unscrew the cable from beneath the gauge cluster housing if not already detached from the wheel. If it is already detached from the wheel, you can skip this step. Clean the work area beneath if needed.

Step 4: Disconnect the electrical harness from the fuel level sending unit.

Step 5: Remove the screws from the fuel level sending unit.

Step 6: Ease the fuel level sending updward. Avoid a mess by allowing fuel to drain from inside the tube back into the tank.

Step 7: Remove the cover from the bottom of the fuel level sending unit tube.

Step 8: Remove the float from the fuel level sending unit tube. You might have to tap the tube a few times on a hard surface to shake it loose.

Step 9: Carefully clean contamination from the fuel float. Be careful to not dislodge the counterwight. Sand the rounded surface with 120 grit sandpaper. There is no need to sand the flat surface.

Step 10: With the counterweight facing the top of the sending unit tube, re-insert the fuel float. Place your palm against the bottom of the tube and move the ends up-and-down while listening and feeling whether the fuel float moves freely. If it does not, then lightly sand the surface some more until it does.

Step 11: Reassemble. Be sure to reconnect the electrical harness for the gauge. Also remember to reconnect your speedometer cable.

Step 12: Insert the key into the ignition and apply power. Observe fuel gauge travel.

That's it!
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