2003 Fatboy fuel injected. I just had the fuel gauge repaired. I put about 170 miles, fuel light comes on, when it filled the tank, it only took 3.1 gallons. The tank was filled to the top. After about 80 miles the fuel gauge is registering1/4 of a tank remaining--then it only takes about 2.3 gallons--any ideas?
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.
SOURCE: Fuel Gauge reads empty all the time
The circuit for a fuel gauge is: battery positive through the gauge resistor to the sending unit to the fuel tank(sheet metal) to the chassis to the battery negative. If you didn't remove the sending unit the most likely problem is the fuel tank is not grounded to the frame. Scrape some paint at the rear mounting bolt where you can't see it and re-tighten the bolt. If you removed the sending unit, check the cork gasket. There should be a staple in it that is the connection to the sheet metal. No kidding.
SOURCE: Is it possible to clean the fuel pump of my 2002 Fatboy FLSTFI?
Try running sea foam a couple of times.
SOURCE: Fuel injection Harley Davidson 02 Fatboy
System is self bleeding. You may have disturbed some debris that has gotten in the fuel injector/s. Try running some fuel injection cleaner through it and see what happens.
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D: could be a coil, temperature (heat) can cause an open internally. Could also be the cam rotor sensor (more likely) located under the timing plate on the right side crank case (2 rivits or screws). you can cause this to happen for testing with a hair dryer. Start bike cold, and heat item in question and see if it shut's down early. Could possibly be an ECU, but when they fail it's usually done for good.
SOURCE: 2005 Heritage Softail Classic Fuel Gauge
Considering how tricky the fuel sending unit is to remove for some people Im gonna reccomend you take it to the dealer simply because even seasoned techs break things in the tank
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