Online: crowster69

Sportster fuel level sensor install & road test

  • Kingchops
    Kingchops
    6 years ago
    HD now make a decent fuel gauge for Sportsters, the only problem is you've got to install the fuel level sensor inside your tank (part: 61200008A).  My bike came with the combination speedo/tach gauge (part: 70900100C), which has the fuel gauge and range displays built in.  But it didn't have the fuel level sensor in the tank, so these features didn't work.  I bit the bullet and decided to install the fuel level sensor.  It was a bit of a pain getting the fuel pump assembly out and back in to the tank, but it's done.  I now have a decent digital fuel gauge with range function on the Sporty.


    Getting the fuel pump assembly out of the tank.  This is difficult because of the tight clearances around the sides.  I found removing the spring clip from around the fuel filter housing made it easier to jiggle it out of the tank:

    HD Forums Australia - 20170801_192933.jpg



    The fuel level sensor kit from HD, part number: 61200008A, $215 bucks at Harley Heaven:

    Here's the fuel pump assembly with the basic Sportster low fuel light sensor (small cylinder part in the middle).  

    You have to remove the low fuel light sensor and replace it with the fuel level sensor from the kit.  Here's a pic of the low fuel light sensor removed.  The level sensor is taller than the low fuel sensor, and it needs to clear the fuel hose at the top by at least 1.5mm.  So I found that I needed to bend the metal mounting tab out to get the clearance.  Unfortunately this makes getting the assembly back into the tank more difficult.


    Pic with upgraded fuel level sensor installed:

    Everything back together and configured.  At first I couldn't get the option to enable the fuel gauge in the speedo setup.  This setting allows you to also select your tank size.  

    ** I had to pull the main fuse to get the speedo to reset itself so I could configure the fuel gauge.  Once that was done I got the option to enable the fuel gauge and select tank size.  **


    The last part of the install requires you to fit a jumper plug to the low fuel sensor harness connector.  On 2014 model Sportsters this plug is located under the ECU electrical cover, behind the rear cylinder.  See my post below with a picture of the jumper.

  • Neale
    Neale
    6 years ago
    Thanks.
  • TC883
    TC883
    6 years ago
    Great info mate, thanks!
  • shadowarrior
    shadowarrior
    6 years ago
    Awesome walkthrough Kingchops. Thanks for the pictures as well. I've got the same combination meter but from reading other forum posts, they mentioned we had to install both the meter and the fuel sensor together. Thanks for confirming that statement is wrong. Looks like the sensor is going in my next list of upgrades :)
  • shadowarrior
    shadowarrior
    6 years ago
    Interesting. Mine's a 2012 Sportster Custom XL1200C from US (1HD). It has the same combination meter but I don't have fuel gauge showing up. I also have these connectors not connected to anything, from some of the posts, it was related to the digital speedo/fuel sensor. Is there any way to physically check if the fuel sensor is installed, without taking the fuel pump assembly out? I have no idea what these connectors are for. 




    This is what my speedo looks like (from when I was taking pictures of the light install :D )




    Underneath the tank:





  • Kingchops
    Kingchops
    6 years ago
    My bike is also a 1HD U.S model.  From what I've read, the U.S model 1200C's come with the combo gauge already installed from the factory.  Your gauge looks the same as mine and is effectively the same but it's a different part number for 2013 bikes and below.  On 2014 Sportsters and up the electrical system changed quite a bit, thus the different part number. 
    The only way you can tell if the fuel level sensor is installed from the outside is to check the jumper connector.  I think you've got it there in your second photo on the side cover.  If there's a jumper wire in the end of the connector you most likely have the fuel level sensor installed.  

    The fuel gauge needs to be enabled to show on the display.  Most likely your bike is in the same state as mine was, having the fuel gauge switched off because you don't have the fuel sensor installed.

    Here's a pic I downloaded showing what the jumper connector looks like on mine now the fuel sensor is installed.  Yours is under the seat but the same connector.  When it's not installed the plug you see below is just solid plastic on the end.


  • shadowarrior
    shadowarrior
    6 years ago
    I've got a long plastic cover connected to it (shown sitting on the side panel in the second picture) I think and the plastic cover has 3 pins which goes inside the connector. Wonder what the grey connector next to it is for. I think the 2013 and up models got CAN BUS? 

  • Kingchops
    Kingchops
    6 years ago
    The three pin black connector looks like the correct connector.  If the cap that goes onto that connector has three pins in it, then it's the default connector for the low fuel light.  The cap that comes in the fuel level sensor kit has only two pins.  You assemble it using a jumper wire that also comes in the kit.  Not sure what the grey connector is.  
  • Krash Kinkade
    Krash Kinkade
    6 years ago
    Be handy knowing how much fuel left in tank!
    what range do you get and how many liters does tank hold.
    I'm still with carb Harley's never ridden an efi yet. I ride till reserve then fill up.
  • Kingchops
    Kingchops
    6 years ago
    I syphoned most of the fuel from the tank before I took it off. I just used a hose through the filler cap. There was a tiny bit of fuel left in it. So once I got it off, I strapped the tank sideways to a chair with the fuel pump at the top.  You can see my dodgy method in the pics.
  • Kingchops
    Kingchops
    6 years ago
    Today is the first chance I've had to fill up the tank and road test the new fuel level sensor.  The first good sign on taking the bike out was that the range display started working.  After the install the fuel gauge showed two bars but the range display only showed "LOW RNG" low range.  But once the bike was in motion I started to see the "R nnn" display.  
    I then proceeded to the servo and filled the tank up.  On starting the bike after fill up it took a few seconds but the fuel gauge updated to show four bars (full tank).  The range display also updated to 232km.  This didn't seem accurate, but the instructions for the fuel gauge state that the range is updated during the first 48km's.  So I took the bike on a short run and was pleased to see the range slowly increase the farther I rode.  It got up to 245 and then started to go down slightly.  But by the end of my run which was 33.2km's the range now displays 239km's remaining, so 272km total.  This seems close to what I'd expect.  Possibly a little low, but considering it was mostly city riding and I didn't do the 48km recommended, I'm pretty happy with the numbers.

    At least this seems to prove once and for all that the fuel level sensor can be installed after the speedo/tach gauge.

    Range display after filling tank to full and doing a 33.2km test run:


    When I filled up at the server I set trip meter A to zero, so I could see how far I'd gone on the test run:


  • shadowarrior
    shadowarrior
    6 years ago
    I never knew they had a range display as well! Time to sweet talk the Mrs on letting me buy the sensor :|
  • Kingchops
    Kingchops
    6 years ago
    Yes, you get both fuel gauge and range with the level sensor.  For me the range is what really makes it worth the trouble and cost.  The fuel gauge is good to get an idea of what's in your tank, but the range is where the real value is.
    I recall reading in my owner's manual (2014), even the factory gauge should display the range feature.  So for those without the upgraded speedo/tach they should still be able to get range if they have the level sensor installed.  You'd have to check what year the range function was introduced into the factory gauge, not sure how far back it goes.
  • TC883
    TC883
    6 years ago
    Hey Kingchops, does that table mean that my 2010 has the fuel level and range function built in, and all I have to do is install the fuel level sender to make it work? Note, mine is an Australian delivered 2010 model with what I would call the 'basic' speedo and no tacho function. Cheers, TC
  • Kingchops
    Kingchops
    6 years ago
    Just thought I'd provide an update on the fuel level sensor after the first tank of fuel.  I've managed to ride the bike 250km on a single tank with a mixture of 80/20 highway/city riding.  The level sensor worked as expected and bars on the fuel gauge went down as range went down.  The fuel gauge went down to one bar at around 70km remaining on the range display.
    I also found out that the low fuel light still works.  Low fuel light went on at around 85k remaining on the range display.  Once I was below 60km on the range display, the fuel gauge went down to no bars and "LOW RNG" now displays on the range display.  

    The trip meter was at 210km when range remaining was at 70km.  So at 250km currently on the trip meter I'm down to my last 30km going by that.  From a visual inspection of the fuel in my tank, I reckon there's at least one or two litres remaining so I'm sure I'd get close to another 30k from the current tank.  This would give a total range of 280km.

    It's a bit disappointing that the range display switches to "LOW RNG" below 60, I'd prefer if it kept going lower.  But in any case I'm very happy with the accuracy of this device.  


  • Kingchops
    Kingchops
    6 years ago
    That looks like the "check engine" light.  They may have triggered some errors when installing something.  What fuel tuner do you have?  I know my FP3 allows you to read error codes.  That might be something to check.  Otherwise take it back to the dealer, they should be able to diagnose it.
  • Kingchops
    Kingchops
    6 years ago
    I was going to say is it there all the time, because the engine light does flick on when ignition is turned on.  You said it was below the zero, I can't see anything else in the picture?  Do you have a photo of it?
  • Kingchops
    Kingchops
    6 years ago
    I just had a look at my first post where the link is to the gauge and you can see that warning light better in this picture on the HH site.  Good question, I have no idea what that is.

  • Ferrett62
    Ferrett62
    6 years ago
    Looks a bit like the cruise control dash  light in my car.
  • Kingchops
    Kingchops
    6 years ago
    Good to hear that it's working for you.  
    I've been commuting to work, and I had my range down to 14km.  I filled up yesterday and the tank took 13.1 litres (4.5g tank).  I'm a little surprised that the 4.5g tank seems to only have a usable capacity of around 14 litres.  I would have hoped for a bit more.  But it all adds up, with say 20km per litre and 14L tank that makes 280.  280 is what my max range reports on a full tank at highway economy.

    I've also noticed that the max range seems to learn based on the last tank of fuel.  A few weeks back when I was doing highway riding, I was getting a max range of 280 with full tank, now with the city commuting, it reports around 250 with full tank.

    All in all, it's a bloody great mod.