How to adjust the fuel gauge reading
by Chuck Chiodini ,January 2000

1. Ride the bike until the fuel gauge measures as  low as you can stand.
2. Place the bike on the side stand.
3. Remove only the right side cover to reveal the fuel sending unit located on the right side of the fuel tank.
4. Remove the four 10mm nuts holding the sending unit on and slide the sending unit out 1". No fuel spilled out because the bike was leaning on the side stand. Since the sending unit is only moved 1", there is no need to disconnect from the wiring harness.
5. Siphon all the fuel out of the tank via the sending unit hole. Easy because the remaining fuel is sloshed to the "low side".
6. Inspect inside bottom of tank for rust and foreign objects. Insure the fuel screen is intact.
7. Place bike on center stand and level bike by placing blocks under the front tire. I used a carpenter's level on the seat to make sure but a glass of water or beverage of your choice, would work just as well.
8.  Turn the ignition ON and bend the fuel float rod on the sending unit down until the gauge reads just to the left of the red zone (or wherever you prefer) with the sending unit reinstalled. Mark the rod at your "bend point" so you will adjust it at the same place every time (saves lots of readjustment time).
9. IMPORTANT STEP! Before bolting the plastic back on, start the bike and rev it to 4,000 rpm for 3 minutes to ensure the gauge reading is where you want it on EMPTY. On my bike, there was a slight difference due to the increased voltage (My summation). Readjust float rod as necessary. There's enough fuel in the lines to accomplish this step without adding more gas to the tank.
10. Bolt everything back together and put � gallon of fuel in tank.
11. Start the bike and rev it to 4,000 rpm for 3 minutes and make a mental note of where the gauge reads when you have � gallon in tank. Mine read one needle width in the red zone.
12. Now confirm your adjustments. Place your spare fuel can in trunk and go for a ride until you run out of gas. Mine sputtered to a stop one needle width to the left of the red zone. NOTE: WalMart sells a 1 gallon plastic fuel can for $1.92 that fits great in the trunk.

RESULTS: The bike now will run out of gas at the end of the red zone (like it should) and instead of "being in the red" and nervous at 150 miles, the gauge now reads a comforting 1/4 tank. It's only a mental thing, but the bike "seems" to have a longer range now.

     To double check my work, I just had to go on a short 300 mile putt through the Ozarks following Arkansas Scenic Highway 7 from Hot Springs Northward. Couldn't believe it was 68 degrees in January! Only got wet for a few hours but the mink oil applied to my leathers kept me dry and warm. Nah-nah de nah- na to all you folks in the "frosty country". I must have had a great time in the twisties because I blew a front fork seal. Alright! Back to wrenching!

Ride like your life depends on it!
Chuck Chiodini in Heber Springs (under tornado warning today)
89 PC "Scooter" (bleeding from the right front fork)