Removal
1. Remove main fuse. See 7.3 SYSTEM FUSES AND RELAYS.
2. Draw fuel gauge connector out of tunnel under left side of fuel tank and disconnect.
3. Remove terminals from connector housing. See A.21 TYCO 070 MULTILOCK UNSEALED CONNECTOR.
4. Remove convoluted tubing from wires.
5. Remove the gauge from the fuel tank. Do not twist during removal. Pull upward just far enough to free the gauge from the fuel tank.
6. Remove fuel gauge from motorcycle while feeding wires and terminals up through tube.
7. If reusing gauge, inspect rubber gasket for damage.
Replace gasket if necessary. Install new seal with flat side contacting edge of gauge.
Installation
1. Place new fuel gauge assembly next to discarded unit and cut wires to proper length.
2. Crimp new pin terminals onto wires. See A.21 TYCO 070 MULTILOCK UNSEALED CONNECTOR.
3. Install gauge:
a. Feed wires down into tube while lowering gauge into position.
b. When terminals exit bottom of fuel tank, gently pull wires while lowering the fuel gauge.
NOTE
Do not twist the gauge during installation.
c. Hold the gauge firmly and press downward until it snaps in place.
4. Install convoluted tubing on wires.
5. See Figure 7-86. Install terminals into connector housing. See A.21 TYCO 070 MULTILOCK UNSEALED CONNECTOR.
6. Route connector forward and then inboard between front of crossover hose fitting and bottom of fuel tank. Mate fuel gauge connector and push into tunnel of fuel tank.
7. Install main fuse. See 7.3 SYSTEM FUSES AND RELAYS.
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