BikerRon wrote:
This is what you'll be replacing. Pay attention which way the float's arm is positioned when you remove it. Been known to be installed pointing the wrong way.

Do not force it during installation. Don't want to bend the arm out of adjustment or break the plastic parts. Can be a bit of a Chinese puzzle, sometimes. Go slow and ease it back in.



Hey!!!, That's my hand and tank in that pic!!!

Yeah, the sending unit is probably shot but they can be rebuilt. Are you getting any blinking Engine light? If you are getting 8 blinks and about a 2 second gap then 8 blinks then it's telling you the sending unit isn't sending info.

If it has come apart in the tank you may hear the float rubbing up along side the inside of the tank as well, but sometime they just fail electronically.

I replaced mine this winter, all but 1 of the wipers broke off. The gasket comes with the sender.

Thanks to all on cluing me in on the sending unit. I'm trying to find a good youtube video on removing the tank from a 2001'ish Road Star. Any good instructional videos or guides out there? I have ordered the sending unit and should be getting it soon.

olesparkie wrote:
Thanks to all on cluing me in on the sending unit. I'm trying to find a good youtube video on removing the tank from a 2001'ish Road Star. Any good instructional videos or guides out there? I have ordered the sending unit and should be getting it soon.

Real men don't need no stinkin' video!!!

Close the petcock and run the engine until it quits.
Remove the Speedometer bezel (3 - 5mm hex screws) and disconnect it or place it over the handlebars.
Remove the fuel line from the petcock.
Remove the breather line from the top of the tank.
Remove the seat.
Remove the bolt from the rear of the tank (10mm wrench).
Lift the rear of the tank slightly to find the cable with the green connector. Disconnect this.
Slide the tank to the rear to disengage the rubber mounts.

Reverse this to remount the tank.

2 things that you will do at some point when reassembling:
1) Forget to connect the sending unit (green connector).
2) Forget to reconnect the fuel line to the petcock.

Don't ask me how I know this.

Like Joe said above, removing the tank is pretty simple when you get actually get started and can see it. There are two plugs for the speedo assembly kind, of look where the wires for both are routed up at the front end of the tank. You may have to wiggle the plugs out one at a time from under the tank to disconnect. I have an 01 also, I know Phil's 06 has a little longer wires and a little different routing. Again nothing difficult just good to keep in mind and then remember you may have to wiggle the connectors back down under the tank after reconnecting so the speedo bezel sets down flush. (Cell phone pictures while taking it apart are a wonderful thing if you are getting older and forgetful like me ) One thing that I have not seen mentioned or maybe I missed, do not count on the new gauge reading exactly where your old one did with the same amount of fuel in the tank. My new one was off about a 1/4 of a tank. Our 01s hold about 5.3 gallons of fuel. I had 2-1/2 gallons measured out and bent the float wire (do this in very small increments - it does not take a lot) until I had 1/2 tank reading on the gauge with the bike setting upright. Do not forget the gauge averages so it needs to set a couple minutes for a true reading. I think I had to drain and pull the tank maybe 3 times to get it where I wanted. You can see multiple posts of folks complaining they can only put 3 gallons in when the bike reads empty - this is why.

Father_Pobasturd wrote:
The thing I find amazing is that you have been a member here 5 years and this is your first post. A true testament to the dependability of the Road Star.

I think it's a testament to the quality of the forum.

There are very few new questions to ask, this forum and the members have covered everything so well that everything can be found with a little research here.

(Including this question.. )

uggg on the real men not needing a video. that's gonna leave a mark.

Yeah....typical for the RS....mine did it, I changed the sending unit and it works perfect!

Come on guys!Even if you've changed 10 of them you are going to watch a youtube video if you see it just to make sure they are doing it correctly! Tell me if I'm wrong!

Replaced this weekend. Holy mackerel was it easy. New sending unit works like a charm! Next project will be upgrading my stator and regulator.