[SkyKing]

My wifes 2000 FLSTC has developed a leak at the bottom of the tank, where the fuel gage wiring comes out. I assume I need to replace the gasket for the sending unit. I have studied the service manual but am still unsure of what to expect when I pull the gage. Are there any tricks I need to know about? Is it going to be obvious, once I get it loose? Thanks in advance for any insite/advice. Sky

[FLHTbiker]

Originally Posted by SkyKing

My wifes 2000 FLSTC has developed a leak at the bottom of the tank, where the fuel gage wiring comes out. I assume I need to replace the gasket for the sending unit.

Woosh, a lot of gas if you don't drain the tank first.

[SkyKing]

I kinda figured I would have to drain the tank. But do I need tiny little hands to get into the tank for anything? Or...will the entire unit come out so that I can work on it with my clumsies? Service manual didn't do the job justice.

[FLHTbiker]

Skyking, the last two bikes I worked on and had to pull the unit out of the tank they came out in one piece. The fuel gauge sender unit in the Harley repair manual for my softail shows a plate at the bottom with torx screws and the wires are attached to that. You have to remove the entire plate If you don't have the HD service manual I would suggest investing in one as mine shows the steps to remove it.

[SkyKing]

Thanks for the replies. I have the service and parts manuals. After reading them I still was not sure if I had to get a special long bladed 'Torqs' driver or if normal tools would do the trick. While I slave at my regular job my wife is out rounding up parts. Hope to repair tomorrow morning (work from 2pm till 3 am). Just trying to be as prepared as possible when I start taking things apart.

Don't know why they even put a gage in the tank. I don't trust them anyway.

[FLHTbiker]

I bought a Valkyrie Interstate back in July, just because I got it so cheap. Anyway the bike started cutting out when the fuel would hit about 1/2 tank. So tonight I pulled the tank dumped out the gas and pulled out the petcock from the bottom of the tank. The fuel filter for them is up inside the tank, and someone had added a second fuel filter from a 1500 Goldwing in line to the carbs. The initial fuel filter had some crude and debris on it so I cleaned it real good. Removed the second filter (not needed). Installed a new air filter that I stopped and picked up on the way home. The old one was pretty dirty. They even put the air filter under the tank which means when you replace the filter you gotta pull that 7 gallon tank off and it better be low on fuel as its heavy. Put everything back together and runs great. I know what you feel like though as I don't have a shop manual for this bike and it was play it by ear removing everything.

[SkyKing]

Well...it stopped leaking over-night. I will still get a new gasket, but it will hang on the wall until the leak starts again. My wife rode it some yesterday. Maybe that's all it needed. maybe it will keep for one of the winter projects.

[bikerjim1]

Fuel leaking is not something I'd take lightly! Better to fix it now than to deal with the scoot burning on the side of the road or even worse, with your ol' lady on it! Take care of it while you have control of the situation!

[hotroadking]

OK under the tank you'll find a connector on that wire, disconnect it from the main harness, you can remove the wires from the connector if you wish but it's not necessary this allows you to pull the gauge up farther.

The fuel gauge comes out as a unit so you can pull it out, a little wiggling will do the trick, once it's out note where the wires go to the terminals,

Remove the nuts and wires be careful not to drop them.

let the guage hang over the side of the tank, wrap it with a cloth to keep from denting or scratching tank.

Under the gauge will be some screws holding the cap for the gas tank float.

Remove them and the float and replace the gasket and reinstall.

[SkyKing]

Thanks. Will try and replace gasket on my next days off. (About 5 days away). Was going to work on it this morning, but since it stopped leaking, at least temporarily, I'm putting it off until I can perform better. I'm working 12 days on - 2 days off, from 2 pm until 2-4 am. I'm sure to drop something into the tank in my present state of fatigue. First good nights sleep and this project is number one. Your description was much clearer than the service manual. Thanks again.

[SPORSTERBOY]

Speaking Of Draining The Tank. When I Went 2 Paint Mine, I Unhooked Everything On It And Still Had 2 Drain The Gas From The Gas Cap Hole ? Is That Just The Way 2 Do It?

[chucktx]

that is a way to do it.....or out one of the petcocks............or stand back and put a 45 hole in it,,,,,,should run out real good through that!!!
chuck

[SPORSTERBOY]

Thats What I Don't Understand Chuck? If The Gas Cap Is Off And The Petcock Is Out, Why Does'nt The Gas Come Out Of The Petcock Hole?

[chucktx]

if gas is not comming out the pet cock it is blocked by something. take a small wire and see if it goes allthe way into the tank.......the best way is to remove the petcock completely from the tank, that gas should flow now....and either rebuild the petcock or replace it. if gas doesnt flow with the petcock removed, i bet the tank was sealed with a sealer and it has fallen across the opening.....hope this helps
chuck