I have a 2003 Fatboy fuel injected. I recently got the fuel gauge repaired. After leaving the dealer, I put 170 miles before the fuel light came on. I filled the tank to the top, and it only took 3.1 gallons of fuel. Now after about 80 miles, the fuel reads 1/4 remaining. When I fill it to the top, it only takes about 2.3 gallons--any ideas?

Have you checked the throttle body to see if the ventury butterfly is operating properly? Its most likely a fuel prob. You may want to check fuel pressure as well. So e parts stores will rent or loan a gauge to check it at the fuel injection rail at the intake manifold. I would start there to make sure you are getting proper pressure and volume. Ask your parts store or dealer for what pressure should be. And make sure you leave the guage on for ten min or so while the car sits not running to see how fast pressure falls.

To clean the carbureted model's filter, you drain the gas from the tank, remove petcock and filter, clean filter with compressed air, reinstall. The fuel injected model requires that you drain the tank, remove the entire pump assembly from inside the tank, and then replace the filter (it can't be cleaned).

The carbureted model's filter is supposed to be inspected and cleaned every 20k miles. The fuel injected model's filter is supposed to be replaced every 25k miles.

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.

sounds like you may have the wrong gauge for the sender or a sender unit wrong for the gauge ,take it back to the dealer and get them to sort it out cheers

The mass airflow sensor shouldn't be that expensive and usually they are easy to replace so there shouldn't be much labor involved. I''m guessing less that $100 should cover it.

If the bike came with a fuel gauge, no problem. Just work the fuel gauge up out of the tank. It's held in by a rubber o-ring. The wires under it are very short so be careful. The sender unit is inside the tank. You'll have to determine which is the problem piece and replace it.

If your bike did not come with a fuel gauge, you'll have to purchase a left side fuel tank if that's the location of the original fuel gauges. I do not know where Harley puts the fuel gauges on the Softails. If they have a fuel gauge on them, they are fuel injected. I do not work on fuel injected bikes, carbs only. Sorry.

Good Luck
Steve

# 07187C: Special Coverage Adjustment - Instrument Panel Cluster Gauge Needle Function - (Mar 20, 2009)
Subject:
07187C -- SPECIAL COVERAGE ADJUSTMENT - INSTRUMENT PANEL CLUSTER GAUGE NEEDLE FUNCTION

Models:
2003-2004 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT
2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT (U.S. ONLY)
2003-2004 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE
2005 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE (U.S.ONLY)
2003-2004 GMC SIERRA, YUKON, YUKON XL
2005 GMC SIERRA, YUKON, YUKON XL (U.S. ONLY)

THIS BULLETIN IS BEING REVISED TO INCLUDE CERTAIN 2005 MODEL YEAR VEHICLES IN THE U.S. ADDITIONALLY, FOR U.S. 2003-2005 MODEL YEAR VEHICLES, GM WILL PROVIDE THE INSTRUMENT PANEL CLUSTER (IPC) ONLY, AT NO CHARGE TO THE CUSTOMER FOR VERIFIED FAILURES BETWEEN 70,001 MILES (110,001 KM) AND 80,000 MILES (130,000 KM). ANY ADDITIONAL COSTS, INCLUDING LABOR TO REPLACE THE INSTRUMENT PANEL CLUSTER, WILL BE THE RESPONSIBILITY OF THE CUSTOMER. DEALERS WILL BE RESPONSIBLE FOR THE RETURN OF THE CUSTOMER'S IPC BACK TO THE ELECTRONIC SERVICE CENTER. PLEASE DISCARD ALL COPIES OF BULLETIN 07187B, ISSUED SEPTEMBER 2008.

CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE DEALERSHIP TO ARRANGE AN APPOINTMENT IF THEY BELIEVE THEIR VEHICLE HAS THIS CONDITION. THE CUSTOMER IS BEING ASKED TO PROVIDE THE VIN SO THE IPC CAN BE ORDERED IN ADVANCE OF THE SCHEDULED APPOINTMENT. THIS WILL ELIMINATE THE NEED TO KEEP THE VEHICLE OVERNIGHT. DEALERS ARE TO OBTAIN THE VEHICLE MILEAGE WHEN SCHEDULING A SERVICE APPOINTMENT. THE VEHICLE MILEAGE WILL BE REQUIRED WHEN PLACING AN ORDER FOR THE IPC.

Condition

Some customers of all 2003-2004 model year and certain U.S. 2005 model year Cadillac Escalade, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, and Tahoe; and GMC Sierra, Yukon, and Yukon XL vehicles have reported that one or more of the instrument panel (IP) cluster gauges stick, flutter, or become inoperative. This may cause inaccurate readings, including the speedometer and fuel gauge. Special Coverage Adjustment This special coverage covers the condition described above for a period of 7 years or 70,000 miles (110,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.

Dealers are to replace the instrument panel cluster after the condition has been verified. The repairs will be made at no charge to the customer.

For verified failures between 70,001 miles (110,001 km) and 80,000 miles (130,000 km) on U.S. vehicles, dealers are to provide the customer with an instrument panel cluster (IPC) only. Any additional costs, including labor to replace the instrument panel cluster, will be the responsibility of the customer. Dealers are responsible for the return of the customer's IPC back to the Electronic Service Center.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 28, 2007 for 2003-2004 model year vehicles, and March 23, 2009 for 2005 model year vehicles, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 28, 2007 for 2003-2004 model year vehicles, or March 23, 2009 for 2005 model year vehicles, must be submitted to the Service Contract provider.

any bad fuel in your area,low petrol recently,,may need to get dealer or good mechanic to pull fault codes from computer,not expensive to do,but repair depends on fault,need to look further,any car situation changes recently that may explain it,may be simple like spark plug lead

I would check the oil pressure sensor and the oil pump itself. You can take the sensor out and use a mechanical gauge to check the oil pressure. If the oil pressure is within specs, you need a new sensor, if not, you need a new pump.