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Mechanical Fuel Gauge Adjustment

COG Digest 1971 From: Steve Long

The fix is easy but a little  time consuming. To make it easy I would ride the bike until you are just about to flip to reserve or have just flipped over.  Make a mental note where the needle reads at this point (probably deep into the empty territory). I would do this procedure on the side stand to get the most realistic riding reading.

1.  Pull the tank by removing the two bolts, 5 hoses and the sending unit  wires.
2.  Put the tank on its side (on a nice towel) and pop off the air vent  cover on the under side with a screwdriver..
3.  Unbolt the four bolts that hold the sender and fish it from the tank.
4.  Take the wiring off of the tank and go back to the bike,  sender in hand. Reconnect the sender to the wiring on the bike.
5.  At this point you can decide if you want to increase the range of the tank by SLIGHTLY bending the limiting tab to allow         the gauge to read beyond full.  Watch your gauge and stop the adjustment process when you are happy.
6.  Change the angle of the bend in the float arm from just a bit more than  90 degrees to a bit less to adjust how it reads at         that point in time...
7.  Re-install the sender in the tank, connect the wiring and set it on Connie... see what you think.
8.  You can remove,  adjust and reinstall as much as you like.
I have mine set to go just past full and I flip over to reserve just as the gauge is entering the 'red'.

Article By: Steve Long

Updated January 2005

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