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How to Remove a Harley Fuel Sender

Harleys with electronic fuel injection are more common now. Everything on a fuel-injected Harley is connected together through what is essentially a black box called an electronic control module. When one component of the electronic chain breaks, it is sometimes necessary to test several components. One of those components is the fuel sender, which provides data to both the gas gauge and the fuel pump. The sender is usually removed to perform what is called a "fuel sender test."

Instructions

1

Remove the seat by loosening the Allen screw that connects the seat locking tab to the rear fender.

2

Grab the sideplate on the right side of the motorcycle with both hands and pull. Pry the full pump fuse from the fuse block with a small flat head screwdriver.

3

Start the engine in neutral and allow the engine to run until it stalls. Operate the starter for 3 seconds after the bike stalls.

4

Disconnect the negative battery wire from the battery terminal with an open end wrench.

5

Remove the acorn nut and washer on instrument console with an Allen wrench. Separate the instrument console from the fuel tank.

6

Unplug the plastic fuel-pump module connector from the wiring harness. Remove the 10 fuel tank top-plate fasteners with an Allen wrench. Remove the top plate.

7

Reach into the fuel tank and push the fuel pump housing down to disengage it from the pump housing and disengage it from the end cap.

8

Pull the fuel pump out of the fuel tank just far enough to reach the fuel gauge sending unit on the right interior of the fuel tank.

9

Pull the fuel sender attachment tab towards the top of the fuel tank to release the sending unit from mounting tabs. Remove the fuel sender and float.