2002 Harley Davidson FXDWG Dyna Wide Glide Logo

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Tim Cornett
Tim Cornett Posted on Apr 09, 2017
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How to replace fuel sending unit on 2002 fxdwg @

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Gregg Mahin

Gregg Mahin

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  • Harley Davidson Master 66,744 Answers
  • Posted on Mar 05, 2021
Gregg Mahin
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Hi, Tim for this scenario you will need your service manual that has all fastener torque specs -fluid capacities and a wiring diagram on the back pages, parts fiche, and owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected]. Good luck and have a wonderful day.
https://www.hdforums.com/forum/softail-models/71330-replacing-fuel-sending-unit.html
http://www.mediafire.com/file/n32mo9rud2vadf4/2002_Harley_Dyna_Service_Manual.pdf/file
https://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://mybikemanuals.com/harley-davidson/harley-davidson-dyna-glide-owners-manuals/
https://www.6ya.com/

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Anonymous

  • 3489 Answers
  • Posted on Oct 26, 2010

SOURCE: location of and how to

These units are in the tank and must be dropped in order to replace.


WARNING Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

  1. Relieve the fuel system fuel pressure, as outlined in the Fuel System Section.
  2. Drain the fuel tank to at most 3/4 of a tank full.
  3. Raise the vehicle.
  4. Remove the fuel tank.
    NOTE The modular fuel sender support assembly will spring-up when the locking ring is moved.
  5. Remove the fuel sender assembly using tool J39765 Fuel Sender Locknut Wrench or an equivalent.
  6. Note the position of the fuel sender strainer for installation.
  7. Support the reservoir with one hand and grasp the fuel sender strainer with the other hand.
  8. Pull the external fuel sender strainer off of the fuel sender.
  9. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned.
  10. Discard the fuel sender strainer after inspection.
  11. Disassemble the electrical connectors from the fuel level sensor assembly of the fuel pump and cover assembly.
  12. Disassemble the fuel level sensor assembly.

    0996b43f802054cc.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Fuel level sending unit on fuel sender (fuel pump) module.


To install:
  1. Assemble the fuel level sensor assembly.
  2. Assemble the electrical connectors to the fuel pump and cover assembly.
  3. Position the new fuel sender strainer on the modular fuel sender and push on the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated on to the sender assembly.
  4. Install the fuel sender assembly into the fuel tank using tool J39765 Fuel Sender Locknut Wrench or an equivalent.
  5. Reinstall the fuel tank.
  6. Lower the vehicle.
  7. Add fuel to the fuel tank.
  8. Connect the negative battery cable.
  9. Reinstall the fuel tank filler pipe cap.
  10. Inspect for fuel leaks.
  11. Turn the ignition switch ON for 2 seconds.
  12. Turn the ignition switch OFF for 5 seconds.
  13. Turn the ignition switch ON .
  14. Check for fuel leaks.

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Hi, Anonymous you could have a faulty sending unit or gauge, there could be a problem with your wiring. On models with the fuel gauge posing as a left-hand fuel cap, the gauge is a press-fit do not try to unscrew it, simply apply ample force lift up in a rocking motion to remove the gauge. Disconnect wires to the gauge and with a set of positive and negative jumpers from the battery connect the positive jumper and flash the negative, the gauge should peg full, if not replace the gauge. With a test light check for power to the sending unit, then remove the sending unit and manually operate the float arm slowly with the correct wiring hooked up to the fuel gauge and sending unit and the ignition on, the gauge should respond accordingly if not replace the float arm assembly. If your fuel gauge registers the incorrect amount of fuel in the tank you can try bending the float arm the necessary amount up or down for a more accurate reading.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected]. Good luck and have a wonderful day.
https://www.hdforums.com/forum/softail-models/858236-want-to-remove-left-side-fuel-gauge-cap.html
http://www.mediafire.com/file/l8mk1291i3fiprh/2000_Harley_FXD_Servive_Manual.pdf/file
https://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/service/document/6300
https://www.6ya.com/ to speak to me personally
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2000 Harley Davidson FXDWG Dyna Wide Glide gas gauge leaking @
Hi, Anonymous you could have a faulty sending unit or gauge, there could be a problem with your wiring. On models with the fuel gauge posing as a left-hand fuel cap, the gauge is a press-fit do not try to unscrew it, simply apply ample force lift up in a rocking motion to remove the gauge. Disconnect wires to the gauge and with a set of positive and negative jumpers from the battery connect the positive jumper and flash the negative, the gauge should peg full, if not replace the gauge. With a test light check for power to the sending unit, then remove the sending unit and manually operate the float arm slowly with the correct wiring hooked up to the fuel gauge and sending unit and the ignition on, the gauge should respond accordingly if not replace the float arm assembly. If your fuel gauge registers the incorrect amount of fuel in the tank you can try bending the float arm the necessary amount up or down for a more accurate reading.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected]. Good luck and have a wonderful day.
https://www.v-twinforum.com/threads/fuel-leak.127097/#post-1375852
http://www.mediafire.com/file/l8mk1291i3fiprh/2000_Harley_FXD_Servive_Manual.pdf/file
https://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://mybikemanuals.com/harley-davidson/harley-davidson-dyna-glide-owners-manuals/
https://www.6ya.com/ to speak to me personally
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Jul 15, 2012 • 2002 Harley Davidson FXDWG Dyna Wide Glide
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Hi, Anonymous you could have a faulty sending unit or gauge, there could be a problem with your wiring. On models with the fuel gauge posing as a left-hand fuel cap, the gauge is a press-fit do not try to unscrew it, simply apply ample force lift up in a rocking motion to remove the gauge. Disconnect wires to the gauge and with a set of positive and negative jumpers from the battery connect the positive jumper and flash the negative, the gauge should peg full, if not replace the gauge. With a test light check for power to the sending unit, then remove the sending unit and manually operate the float arm slowly with the correct wiring hooked up to the fuel gauge and sending unit and the ignition on, the gauge should respond accordingly if not replace the float arm assembly. If your fuel gauge registers the incorrect amount of fuel in the tank you can try bending the float arm the necessary amount up or down for a more accurate reading.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected]. Good luck and have a wonderful day.
https://www.hdforums.com/forum/dyna-glide-models/610079-fuel-gauge-not-working.html
http://www.mediafire.com/file/g3h2vn0nvw3b5wb/2001_Harley_Dyna_Service_Manual.pdf/file
https://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/service/document/6300
https://www.6ya.com/how-6ya-works to speak to me personally.
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Jul 01, 2012 • 2001 Harley Davidson FXDWG Dyna Wide Glide
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2002 Harley Davidson FXDWG Dyna Wide Glide fuel gauge not working @
Hi, Rich, you could have a faulty sending unit or gauge, there could be a problem with your wiring. On models with the fuel gauge posing as a left-hand fuel cap, the gauge is a press-fit do not try to unscrew it, simply apply ample force lift up in a rocking motion to remove the gauge. Disconnect wires to the gauge and with a set of positive and negative jumpers from the battery connect the positive jumper and flash the negative, the gauge should peg full, if not replace the gauge. With a test light check for power to the sending unit, then remove the sending unit and manually operate the float arm slowly with the correct wiring hooked up to the fuel gauge and sending unit and the ignition on, the gauge should respond accordingly if not replace the float arm assembly. If your fuel gauge registers the incorrect amount of fuel in the tank you can try bending the float arm the necessary amount up or down for a more accurate reading.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at [email protected]. Good luck and have a wonderful day.
https://www.hdforums.com/forum/dyna-glide-models/610079-fuel-gauge-not-working.html
http://www.mediafire.com/file/n32mo9rud2vadf4/2002_Harley_Dyna_Service_Manual.pdf/file
https://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?make=hdmc
http://mybikemanuals.com/harley-davidson/harley-davidson-dyna-glide-owners-manuals/
https://www.6ya.com/how-6ya-works to speak to me personally.
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I don't know of a test for the gauge. We used to test gauges in automobiles by taking the sending unit wire loose and then grounding it. When the wire is loose, the gauge will read full scale in one direction, when the wire is grounded, the gauge will read full scale in the other direction. Testing the sending unit is more difficult as it's basically a rheostat or variable resistor. You would have to remove the unit from the tank. The sending unit has a float on the end of a long crooked rod. It can be a real treat trying to get the sending unit out of the tank without bending the rod. If you bend the rod, the gauge will not read correctly even if everything else is right.

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