ADJUST FUEL GAUGE FLOATS 2003 SOFTAIL - 2003 Harley Davidson FLSTC Heritage Classic

- Now days some carburetors are produced which are fixed and no adjustment is provided.The float is made up of whole plastic like material.
Some floats have the copper/metal notch for the adjustment of fuel level.
- Take the carburetor assembly out.
- Remove the fuel bowls.
- Place the carburetor assembly with the floats upward towards yourself.
- Float level gauge and active data list (taken from the workshop manual) is required to carry out the adjustment. But you can simply adjust the float level correctly without any gauge.
- Hold the carburetor assembly at your eye level in such a way that the carburetor No. 1 is in front of you. Behind is No. 2 carburetor, then behind is No. 3 and then the No. 4. Or we can say that the carburetor No. 1 hides the carburetors 2, 3, and 4.
- Examine carefully the floats of all the individual carburetors be parallel to the surface of the carburetor where the float bowl face is seated and tightened.
- Adjust the float level by bending the float notch towards the needle valve (to decrease the float level and to raise the float) or away from the needle valve to increase the float level (to lower the float).

WHAT DTC\'s are set.



You may have a loose, corroded etc wiring connection in the console.



Fuel gauge can be diagnosed as follows:



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 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 testingreplace the gauge itself.

I have the same vehicle and my car actually was full of gas, registered empty & left me on the side of the road..It was the sensor in the fuel line that had to be replaced.

The fuel gauge is held on by an o-ring. Rock the fuel gage side to side while pulling up on it. Be careful as the wires are very short and if you pull too hard, you'll damage the wires when the cap comes off. Down inside the cavity in the fuel tank, you see five or so small screws. If you remove these screws you can work the gauge sending unit out. Raise the gauge sending unit while rotating it in a clockwise direction according to the manual but I found that this is not entirely true. Work the sending unit out the best way you can without bending the arm. I've never taken one of these gauges out of a Softail but I have an a Dyna. You cannot put a fuel cap in the fuel gauge cavity. It is designed for the gauge only.

Good Luck
Steve

Hi, More likely that the float has a hole in it and it would have got sank. Floats are available at your local ford dealer seperate from pump.

Replace the sender unit in the tank

dear friend-take note that you have two feul floats in the tank one works from full to half and the otherside from half to empty.