Is there an easy fix for suddenly inaccurate fuel gauges?

[Frostbite]

I was riding in Cooke City this past weekend and my fuel gauge worked fine Thursday. Friday morning I noticed the fuel gauge read empty (after I had filled the sled up Thursday evening) so I checked the fuel tank to make sure someone hadn't syphoned all my gas. The tank was full, yet the fuel gauge said empty. The gauge read weird (inaccurate) the rest of the trip.

Now, I have about 2-3" of fuel in the bottom of my tank and the gauge says about 3/4 full.

What happened?

Is this a common problem?

Is there a simple fix I can do?

I would ask to have it warrantied (since my sled still has another year of warranty) but, so far my luck in getting things warrantied has been less than stellar.

Any help you can provide would be greatly appreciated.

 

[Ryan-41]

the gauge on my M7 reads empty and I still have a half a tank...I don't think there is a fix!!!!

 

[greeneman]

Mine question would be is the float not floating on the top of the fuel level anymore? Is it seated on both of the guide bars.

 

[shredjim]

Lee - same thing happened to me on the same sled. When I looked into the fuel tank, I could see the fuel guage laying on the bottom of the tank. Common problem from what I hear. So - I JB welded the two metal pieces back into the plastic holder part on the guage itself. Works like a champ so far, knock on wood! 750 miles so far this winter!

 

[Frostbite]

Yes, the float is between the two guide bars and appears to be sitting right at the top of the fuel level in the tank.

 

[ezra]

quick fix twist off cap and peek in huge hole and see how much gas is left

 

[rzjim]

If it's on warranty, get it repaired. $50 deductible after first year. Should not be an issue.

 

[Frostbite]

Thank you!

Now, I just hope Cat doesn't tell me this issue isn't "warrantable" either.

 

[WyoBoy1000]

I think there is supposed to be a twisted piece of metal in the center of the float that moves the gauge as the float comes up, from what I could see it missing. Pull the white plastic piece out of the filler neck and you can see a lot more, look for the twisted metal rod. after you pull the plastic out you can get your hand in pretty easy too.

 

[bart0678]

The float tends to stick on empty. If you smack the side of the tank once its full the float will come back up. I know it sounds crude but it works.
adam

 

[tcpeterson]

x2 on what Wyoboy said. You are missing the twisted metal part from the middle. Mine completely came apart and i just keep an eye on it.

 

[trax]

you are missing the needle rod that goes in the middle of the float. When the float goes up and down it twists the rod and changes your gas gauge readings.Find that in your tank and put it back together and youll be good. That white filler in the neck of the gas tank just pops out.

 

[skimike]

quick fix twist off cap and peek in huge hole and see how much gas is left

exactly, plus I fill up before every ride and check mileage, I coiled care less if it had a gauge, its just a spot for it to leak. a new one costs 54 dollars plus they just pop right out take a flat head screwdriver and pop it out, to put it back in put the rubber grommet in first and use a small amount of grease or ky jelly to install gauge.

 

[Frostbite]

Thanks guys!

It did look like part of the float assembly was missing. I have an old tractor fuel gauge and it had the twisted metal piece you speak of. I guess I'll be going on a hunting expedition in the fuel tank to find it.

Can it be fixed easily?

If I fix it, is there a way to make the fix last?

 

[White Rad]

I pulled my tank to drain and clean it after getting some funky gas in BC and in the process knocked the float assembly out. After trying to get it back in for about 15 min it earned itself a permanent place on the spare parts bench. Its just a cheesy set up I could never figure out why i was burning so much more gas than everyone else until i looked in the tank one day when the gauge said E and found 1/2tank. If your going to try and reinstall it w/ white neck out easy to reach all the way in there i used a small mirror so i could see what was going on in there but you need to get the two wire hangers and the twisted metal rod back in the appropriate holes and i think you need to orient the needle before you get the twisted metal piece back in or it won't read correct. PITA i say just visually check the tank a few time during the day i had to anyways w/ the gauge its was so
far off...

 

[tcpeterson]

Actually it's a little easier than that. Just grab a flat blade screwdriver and pop the gauge out of the tank. The you could JB weld or super glue (what ever adhesive you want) the peices back into the gauge. Once you have it in your had and playing with it you'll see how it goes together. Then just push the gauge back into the hole. I had mine out 2-3 times trying to fix it and then said screw it and as mentioned above it now sits in the parts bin. I have had no issues with leaking or anything of the sort from popping the gauge out.

 

[WyoBoy1000]

Have your dealer order one in then pop yours out, drive down and tell them to warranty it. then pop in the new one and your set.

 

[skimike]

Actually it's a little easier than that. Just grab a flat blade screwdriver and pop the gauge out of the tank. The you could JB weld or super glue (what ever adhesive you want) the peices back into the gauge. Once you have it in your had and playing with it you'll see how it goes together. Then just push the gauge back into the hole. I had mine out 2-3 times trying to fix it and then said screw it and as mentioned above it now sits in the parts bin. I have had no issues with leaking or anything of the sort from popping the gauge out.

they are very easy to work with, you will chit yourself when you see how easy. Ive had them out several times. just don't try to reinstall with the grommet on the gauge , put that part in the tank first then pop the gauge back in

 

[Frostbite]

Thanks guys!

I will try to find the part in the tank and repair the gauge.

 

[Solby]

Had 2 2009 Ms have the outer U shaped metal piece that the float rides between come out of the gauge part. Then all the pieces fall into the bottom of the tank. Just get the pieces out of the tank through the fill hole, then pop the gauge off with a screw driver. Then use lock-tite to hold the U shaped wire back into the gauge. Make sure you time the empty-full needle properly with the center twisted piece of metal.