2004 FLHTCUI:

Replaced the front fairing. Documented all harness and various other parts for correct assembly. Never cut or modified the fuel gauge harness or plug and now it does not work correctly. When the tank is full, the gauge reads almost empty. Filling the tank causes the low fuel light to come on. This does not happen consistently though which has made troubleshooting tricky. Everything was fine before the fairing replacement. I'm an auto tech building emergency vehicles and fairly sharp with electrical issues. I'm quite certain nothing I did should have caused any problem. What might I be missing?

 

The float is kaddy-wampus. Or as we like to say here in Kansas."It's upside down." Or there is a wire crossed in the installation.

 

This ^

There is also another possibility - my gauge was acting wonky

Week ago I replaced the tins - in the process I had to unplug the gauge from the main harness and disassemble the plug (iow remove the pins)

Found the pins to be quite oxidated..., and no dialectic grease

Cleaned the pins w/ steel wool - greased up the connector during reassembly - gauge works better than a new one

Just sumthin to ponder

Ghost