Keepin busy: 2002 Deuce - Page 2 - Harley Forum

shovelmike · #11 10-24-2009, 01:28 PM

The quick check for the gauge is with 12v to the hot side ground the other lead momentarily and the gauge will peg at full. Don't hold it long, just quickly, so as not to damage the gauge.
The more exact method would be to dummy up the circuit using the sender and gauge and see that it reads according to the position of the sender arm.
The speedo and tach simply count the frequency of the pulse from the speedo sensor in the trans and ignition system. I had a post from an automotive forum telling how to check the accuracy of a tach using a battery charger (made possible because the charger current is a 60 hz pulsed DC rather than pure DC). It told what that pulse equalled in RPM for 6 and 8 cylinder, doing the math one could compute 2 cyl. as well but I lost it in a computer crash. Someone on here may recall.
Chances of speedo, tach, and fuel gauge failing together are slim, most likely you will find a wiring problem. See if there is a connector that carries wires related to them, it may be the culprit.

Gas Man · #12 10-24-2009, 02:13 PM

Yeah I need to go over the wiring more closely. but that is chasing tails sometimes. Wanted to test the components. Thought that would be easy with a service manual. Thought they would just tell me... ya know some diagnosis numbers

There is no tach so thats not an issue.

I remember somebody telling me that they know one of the 2002 bikes. If the speed sensor goes bad, it kills the speedo and gas gauge. Maybe that is the problem... not sure.

shovelmike · #13 10-24-2009, 06:55 PM

I would think that the service manual would give a specification in ohms to test the speedo sensor. Also do a visual examination of the sensor to see that there are no metal shavings on it, and that the connector on it is clean and able to provide a good tight connection.
Do a visual inspection of connectors. I would be looking for dirt and corrosion.
Keep us posted on what you find. Ride safe and God bless, Sincerely: Shovelmike.

Gas Man · #14 10-25-2009, 01:08 AM

The 12v to the gas gauge did nothing... just lit the back light. No biggie.

Well I got it figured out. Spoke to the mechanic at the dealer. he gave me a couple a tips. I also found out that if you want electrical help you need to purchase a seperate electrical manual. They are published yearly so I bought one for my set of 2009s. But onward to this project.

First... on the gauge sending unit. He agreed the loose clip I tighted on the pivit pt may be causing some issue. But he said in 2002 or 2003 there was a service bulletin to trim the excess off the float arm. The 1/4" excess hangs up on either full or empty on the inside of the tank.

So I did trim it

Test it by moving the float by hand... Works. Re-installed with a new gasket (old one was dry rotting) and new replaceable sealing screws.

BAM... works with a full tank of 93 octane mixed up with some seafoam.

Second, the mechanic informed me that when cleaning a HD speedo sensor that you must never touch it with your hands, where clean rubber gloves, and clean with brake clean and soft cloth (like microfiber or diaper towel). So if it wasn't screwed up before (proven later it was) then cleaning it with a shop rag would damage it. (I dont get it that but will use caution when handling one in the future. He says its most likely the sensor cause I told him it was covered with shavings when I removed it. So I picked up a new one, which also is a improved (supersuicided version). (pointing at new one)

Got it wired in and yes officer I know how fast I was going.

So I buttoned up the project and calling this one a success. Got everything fixed, tuned, and polished up. All at 50% the budget I was given.

Thanks Mike!

sgtcowboyusmc · #15 10-25-2009, 01:50 AM

WOW I am learning a lot from You Gas Man and ShovelMike!

Great thread with some good info in it!

Thanks

Cowboy

steve dennis · #16 10-25-2009, 11:09 AM

Gasman,very interesting tip on the speed sensor.I've replaced many of these for my riding buddies,but never heard about handling them properly.Guess I was lucky!This forum has saved me trouble and money in the past,just goes to show what a bunch of brains put together can do!Thanks for the thread,Gasman.

Gas Man · #17 10-25-2009, 11:54 AM

Hey I'm with you guys. When he told me that, I learned something new too. Glad you guys liked the thread.

street bob · #18 10-25-2009, 01:34 PM

That was a fun read............ Thanks.

Gas Man · #19 10-25-2009, 10:22 PM

glad you thought so

this is typicall fashion for me