how to install an electric fuel gauge

You've just entered the last town before heading out on the last legof a long, deserted trail ride. You're snowmobile buddy asks, "Howmuch fuel do you have left?" You look down to your fuel gauge, confused.Back and forth, back and forth the dial swings. You answer back, "Halfa tank, no three-quarters, no, a half..."

For the most part, the floating champagne cork has been a reliable meteringdevice, but that method is centuries behind all the technological gadgetsand gizmos that make up today's high performance machines.

Any weekend warrior performance mechanic worth his salt loves tinkeringwith gadgets and we have come up with one that will satisfy your contraptioncraving: an electric fuel gauge.

Electric fuel gauges became a favorite of mine when I evaluated Yamahasnowmobiles. I like the quick and steady, in-your-face reading when bouncingon the trails or roller-coasting through the woods. If AMC built its Pacerwith an electric fuel gauge, why can't a more expensive 90s snowmobile haveone? I know some will argue weight savings or reliability, but the corkand dial unit, compared to an electric unit is, at the most, one pound lighter.The reliability factor is indisputable.

For demonstration purposes, Gary Gruver, Service Manager for AmericanCarriage Company, a Ski-Doo dealer, in Idaho Falls, ID provided assistancefor this fun project. The fortunate recipient? The 1997 Ski-Doo 670 Summit.

The Summit is a snowmobile built with a single purpose where weight savingsis a necessity. Its flashy, white-faced gauges, screamed for more technology,so we obliged and equipped it with an electric fuel gauge.

Installing an electric fuel gauge is a project in which, once the firstcut is made, there's no turning back. So, be sure you have your wits aboutyou because a mistake can be costly (a ruined fuel tank or instrument cluster)and will leave you open to ridicule from your buddies.

If you are doing this project yourself, refer to the installation instructionsas each manufacturer will be different, but the basics are the same. Ifyou are still afraid of seriously injuring your beloved sled, drop it offat your dealer for installation. If you are determined to do this precisesurgery yourself, simply follow these steps as we cover the basics of electricfuel gauge installation.

Just a word of advice- if you are installing an electric fuel gauge ona snowmobile with electric start, disconnect the battery as the first instructionitem. Fuel vapors may be present and one wandering spark might ignite thevapors.

1. Close the fuel supply valve.

2. Disconnect the fuel supply lines and vent lines.

3. Remove the seat.

4. Unplug the tail light connection.

5. Remove the fuel tank's mounting bolts, screws or tie-down strap(s).

6. Remove the fuel tank and thoroughly drain it.

7. With the fuel tank removed, locate the place where the sendingunit will be installed. For the Summit, a pre-molded pattern is alreadypresent on the fuel cell. Other brands and models may not have the patternalready molded in, thus a template may be included in the instructions.

8. Drill a pilot hole in the pattern's center. But before drilling,place a small amount of grease on the drill bit, as this will minimize theamount of plastic particles from falling into the fuel cell.

9. Using the appropriately sized hole saw, in this case a 1-21/32inch hole saw, cut the sending unit's hole. Again use grease on the holesaw.

10. Once the sending unit hole is drilled, drill out the sendingunit retaining screw holes, using the greased drill bit.

11. Clean out the fuel tank using fuel or hot soapy water. Ifusing hot soapy water, ensure the tank is void of any water residue beforeadding fuel. Additionally, add two to four ounces of isopropyl fuel linedryer to the tank when refueling, after installation is complete.

12. Install the float support gasket.

13. Install the sending unit. Be careful when installing the sendingunit as it could be mounted upside down, or can be easily damaged. The floatand pivot-arm are light and fragile, thus prone to bending and being knockedout of calibration.

14. Secure sending unit to support gasket and tank. Tighten downnuts in a cris-cross pattern. Torque nuts down to the specified pounds-per-square-inch.Do not over tighten, as the gasket can get cut.

15. Install new fuel filler cap.

16. Remove windshield.

17. Position fuel gauge template on dashboard (if supplied) andtape down.

18. Before doing any drilling on the dash, make sure all underneathgauge wires are out of the way. Drill a pilot hole in the pattern's center.

19. With the pilot hole drilled, remove the template and usingthe appropriately sized hole saw, cut out the hole for the gauge.

20. Install gauge packing around the back of the fuel gauge andalso on the dashboard.

21. Install the gauge-formed washer.

22. Install gauge holder to dashboard.

23. Install lock washers and nuts.

24. Connect fuel gauge to its housing (gauge holder).

25. Plug in all fuel gauge connections and wires to the correspondingwires as per the instructions: red to red, yellow to yellow and so forth.You may want to use a wire tie to bundle the wires together. When mountingthe gauge make sure it isn't mounted crooked, as this can affect its reading.

26. Re-install windshield.

27. Re-connect all fuel supply lines and open the fuel supplyvalve.

28. Fill fuel tank. Be sure to add fuel line dryer if tank wascleaned with hot soapy water.

29. Start snowmobile and test gauge.

30. If gauge fails to register a fuel level, check all connectionsbehind the gauge and behind the fuel cell (on top of tunnel).

31. Reinstall seat by plugging in the tail light connection andthe electric fuel gauge (if connections are dirty, clean with electricalcontact cleaner). If needed, separate the tail light and sending unit wiresby bundling with a wire tie. Additionally, tape down the electrical wiresto the tunnel.

With the installation complete, fill 'er up with fuel and enjoy. Andthat champagne cork unit? Hang it on your pegboard and keep it as a reminderof snowmobiling in the '70s.