How To Add A Fuel Gauge To A Motorcycle? [A Complete Guide]


How To Add A Fuel Gauge To A Motorcycle

A meter called a fuel gauge measures how much fuel is present in your motorcycle tank. It is necessary for a motorcycle. By the way, if you don’t have a fuel gauge on your motorcycle, let’s learn how to add one. 

Oil level measurements on motorcycles are a bit tricky. Based on my experience of over a decade, it’s not uncommon for me to add a fuel gauge. The installation process is like your elementary school science class. Simply adding some tools with plugging of wires, it will be in its place. 

This article will help you guide through the details of each step. However, anything can go wrong during the whole process. To avoid that, follow the steps.

8 Steps To Add A Fuel Gauge To A Motorcycle: The Most Accurate Way

The motorcycle fuel gauge needs a fully active system to provide an accurate reading. To get that, you need to apply to assure every wiring. Wrong plugging of wires can cause the sabotage of multiple wires. 

That’s why here I come with the easiest way of adding a fuel gauge to a motorcycle. Let’s follow the simple 8 steps to get the job done.

Step-1: Gather All The Repairing Tools Of A Motorcycle

Complete arrangement of tools close to you during the work makes any work easy and fast. A lot of motorcyclists don’t give any importance to this step. Gather these tools to get all set for your every step:

  • A full Allen key set,
  • Screwdrivers,
  • Universal wrench sizes,
  • Hex bolts.

It doesn’t matter if you are an amateur or a professional mechanic, you need to have all the tools beside you. This allows the person to proceed with any step quickly related to the motorcycle. Unnecessary arrangements of tools can make the work incomplete. Hence gather these around and then you are all set anytime, anywhere.

Step-2: Pick The Right Fuel Gauge For Your Motorcycle 

Looks define your taste, personality, and the overall appearance of the bike. Therefore, randomly choosing a fuel gauge for your motorcycle should not be the case here. You should always think about what it will look like on your motorcycle.

For example, if you place a digital fuel gauge on a Harley or any other vintage motorbike, it will break the aspect of the motorcycle. You have to select specifically the similar designs that will go with whatever type of motorcycle it is. 

Now, you can ask if a fuel gauge works just to show the oil level, why does it matter so much? It matters because every dial doesn’t look the same. Also, don’t suffer too much while picking the fuel gauge. Simply just select an analog or a digital one that matches your motorcycle. 

Refrain from selecting the cheap ones. They won’t provide water resistance. Always check the warranty before buying.

Step-3: Separate The Fuel Tank From The Motorcycle

Begin with locating the nuts that are attached to the tank. Make the area clean so that you can work easily. Do check the motorcycle is off. Different types of tanks may differ in this case. But in general, using hex bolts you have to unscrew the bolt. Before that, you have to unplug the seat of the motorcycle. Without removing them, you cannot function with the bolts. When unscrewing is done, steadily remove the tank from its position.  

You cannot fully remove the tanks without unplugging the fuel tap. The fuel tap is the pipe that connects the fuel tank to supply the fuel. Your fuel tank can only be removed after you have unscrewed the tap. 

Allow it to sit somewhere safe. Get an extra hand if needed. A fuel gauge installation requires the fuel tank to be removed. This is because a lot of wiring is underneath the gas tank with a few attachments to be done. 

Besides all of that you just have to follow some rules to plug all the wires. While the separation ensures there is no fuel in it, this isn’t a problem, but an empty tank makes the job a lot easier.

Step-4: Attach Your T-Bracket With The Fuel Petcock

A fuel petcock is a bracket that connects with the fuel tank. This fuel petcock is also known as petcock which controls the flow of gasoline inside your motorcycle. If you find difficulty finding it, look under your fuel tank. 

It is also connected with carburetors. You will find a T-shaped bracket in the fuel gauge box. You have to attach it with the fuel petcock as directed. Do not apply the same mistake by doing it yourself. Make sure the guidelines are strictly maintained. 

As aforementioned, every fuel gauge is not the same and the parts included differ too. So, before any further steps, keep an eye on the manufacturer’s guidelines.

Step-5: Place The Sending Unit 

Sending unit is the device that sends a signal to the fuel gauge which is visible to you. After you have selected your fuel gauge and separated your fuel tank, this is the first step to follow. Along with all the necessary units, you will find a sending unit that is included in the box. This needs to get resized sometimes because the amount of space is relatable. 

Step-6: Secure All The Electrical Wirings

When all the devices are set to their expected place, you have to notice the electrical wirings. These wirings will work just how you arrange them. Now, follow the next steps very attentively. 

First, look at your wiring. Notice all the wires and their color. Keep the provided manual next to you. Observe all the wirings mentioned and do keep in mind that this is very sensitive. One wrong adjustment of wire can damage any other component that is attached to it. 

If you look closely you will find typically there are 3 types of wire. Positive, negative, and an earthing wire is present. The wires should not be seen and it is how you will arrange them. One end of the wiring is going to connect with the fuel gauge and the other with the ignition circuit. 

Step-7: Reattach The Fuel Tank Of The Motorcycle

The fuel tank needs to get back to its place when all the work is done with the wiring and all. Place it according to how you separated it. Be aware of the wiring during the installation. When you have completed preparation for the next step to the final wiring. 

Step-8: Connect The Wires Of The Fuel Gauge

Place the fuel gauge at a suitable place by considering the viewing angles. Do not place where it looks good but doesn’t give a clear view while you are riding. After selecting the right place now you have to connect the back-end wires of the existing electrical wirings you have placed. 

Connect to all the ends accurately. By no means you shall forget about turning the power-on of the power connector. 

4 Useful Tips For Adding A Fuel Gauge Correctly On A Motorcycle: 

The process itself requires so much attention because every part of it is sensitive and related to others. You can’t try to randomly do any of the ways. To make it a bit easier, find out some tips you can use during the process.

Tip-1: Instead of buying the repairing tools separately, buy a full set for your motorcycle. You will find all the necessary tools required for your repair. It is commonly available and comes cheaper than buying individually. Go for high-quality ones, it will last longer with smooth repairing. 

Tip-2: Use an analog fuel gauge all the time. Analog fuel gauges comparatively give an accurate reading most of the time. Digital ones are also good but due to the consistency of analog, they are used worldwide. 

Tip-3: Buy fuel gauges from trusted brands. Usually, they manufacture top-quality ones. High-quality fuel gauges are guaranteed at all times. Using a cheap quality fuel gauge will give you a trash output which will make no help. Sometimes they show you are full even when the tank is empty. Therefore, choose the better ones. 

Tip-4: While separating the fuel tank, confirm that the fuel tank is locked. Fuel may be present in there but always keep the cap close so that it doesn’t bring any harm. 

These tips will help you make your steps even more secure. Apply these correctly as described. 

Related Questions

How Does A Motorcycle Fuel Gauge Work?

A fuel gauge’s actual purpose is to read the level of fuel present in the fuel tank of your motorcycle. Observing the oil level by opening the fuel tank is not possible and which is where the fuel gauge plays its role perfectly. 

At the maximum fuel, the point is a small float attached to a thin rod-like structure. More specifically, this float works like a ball floating on water. It rises as high as water and vice versa. When the fuel level rises, so does the connecting rod and this is how it works.

Why Do You Add A Fuel Gauge To Your Motorcycle?

Especially if you usually fill up less, you need to properly assess how much more you can drive. This is where the fuel gauge comes into play. With a glance at the gauge, you can estimate how much fuel you need to fill up before your next trip. 

The mileage cannot be determined without the fuel gauge. If you don’t have a fuel gauge, you can’t go anywhere in the middle of the road. Better you have one installed.

How Do You Install An Aftermarket Fuel Gauge?

Select the suitable fuel gauge. Then, unbox it from the box and keep the manual safely. Inspect every part included in the box. Separate the gas tank by using the repairing tools. Attach the sending unit and all the essential wires. All steps must be handled with care.

Next, attach the electrical wiring to the main unit. Reposition the gas tank to go for the next step. Start your motorcycle to make it all set. The installation process is the same for the aftermarket fuel gauge. You just have to properly apply the steps that are needed.

How To Install A Digital Fuel Gauge To A Motorcycle? 

The installation of a digital fuel gauge is just plug-and-play. Connecting all the wires accurately will send the signals. Be sure to plug in the main sending unit, unless the fuel gauge won’t function properly. Lastly, make sure all the wire units are connected properly. 

The main difference between the analog and digital fuel gauge is the display, one displays digitally how much fuel is there and one shows with help of a stick present in the middle. Otherwise, the function is the same. 

Can You Put A Fuel Gauge In The Fuel Cell Of Your Motorcycle?

The first thing you need to know is how many ohms your fuel tank is. You have to measure it with the voltmeter. After measuring it with a voltmeter, you will get a reading of 0-90. Next, add all the wirings from the back of your fuel gauge. Apply the correct wires and arrange them correctly. This is how you can add a fuel gauge in the fuel cell of the motorcycle. 

How Do You Match A Fuel Gauge And Sending Unit? 

Open your fuel line first and right after that, keep your petcock on reserve. Separate your fuel tank making it full empty. Disconnect all the wirings of the sending unit from it. Now, turning your fuel tank upside down, you will see the wires in a certain direction. Just after certainly directing the wires, a fuel gauge will match with the sending unit.

How Long Does It Take To Add A Fuel Gauge To A Motorcycle?

Installation of a fuel gauge takes a good amount of time. Right connection of wiring, replacing all the wires, picking the right fuel gauge, all these are the main reasons to take that amount of time. Specifically, it will take you around more than 1 hour to complete the process. 

In some cases, it might take several hours because of the wrong wiring and all the other mismanagements. If you proceed with care, it won’t take you long.  

Approximate Price Range For Different Types Of Fuel Gauge:

Analog fuel gauges are comparatively less than digital fuel gauges. The price varies in manufacturers’ guaranteed quality and housing. However, they are available at a high range of price too.

Types Of Fuel GaugeApproximate Price
Digital Fuel Gauge $60-$300
Analog Fuel Gauge$20-$80

How Long Does A Motorcycle Fuel Gauge Last?

A motorcycle fuel gauge lasts longer than 3-4 years. Depending on the quality of it depends more. You can buy yourself a cheap one and cannot expect a good long-lasting period of it. Moreover, high quality will serve you more. You do have to take care of it too. Otherwise, it won’t last long as you are expecting it to. 

Would It Be Worth Adding A Fuel Gauge To Your Motorcycle?

It is of course worth equipping your motorcycle with a fuel gauge. It will be worthwhile not only for your motorcycle but also for you. It helps the rider estimate how much fuel is left and how to plan the next trip. These are very important for a cyclist to observe. Besides all of that, you save valuable time.

Final Verdict

Adding a fuel gauge to a motorcycle is not complex and also not an easy job to do. It requires accuracy more than time. Handling electrical wires is not as easy as you might think it is. If you are an experienced motorcyclist, you will get the idea. After all, the main part is to get the fuel gauge to work properly. Misreading the fuel is pathetic. 

Ahsan Ullah

Hi guys, This is Ahsan Ullah. I have been riding motorcycle for more than 15 years. In this long period, I have experienced a lot of things about bike riding. Now I am trying to share my experience with you on this website.

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