There’s nothing like the feeling of the open road on your Harley. That is, until your fuel gauge starts playing games with you. That feeling of freedom can quickly turn into anxiety when you’re left guessing how many miles you’ve really got left in the tank.
For over 28 years, us folks at Tri-Starr Radiator up here in North Pitcher, NY have been the go-to experts for exactly this problem. We’re not a big corporation; we’re a family-owned shop run by myself, Dan OHora, and my wife, Samantha. We’re working people, just like you, and we understand the frustration of overpriced or hard-to-find parts. That’s why back in 1993, we set out with a simple plan: to offer quality fuel-sending units at an affordable price.
Based on our 43+ years combined experience in the industry, here are the 5 most common symptoms we see that tell us a Harley’s fuel sending unit is on its last legs.
1. The Gauge is Stuck on “E” (Even When You’re Full)
This is the classic sign. You just filled the tank, but your gauge is stubbornly reading empty. Nine times out of ten, this means the internal rheostat—the part that measures the fuel level—has worn out or lost its connection. It’s the most common failure we see in our shop and the number one reason folks from all over the country send us their units.
2. The Gauge is Stuck on “F” and Won’t Budge
The opposite problem, but just as common. You’ve been riding for miles, but that needle is frozen on full. This usually points to a stuck float or a rheostat that has shorted out. It’s a deceptive one because it makes you feel safe, right up until you’re coasting to the side of the road. Don’t be fooled!
3. The Gauge is Dancing All Over the Place
If your needle is bouncing between empty and full like it’s at a concert, you’ve got an intermittent connection. This is almost always a worn-out rheostat. The vibrations from your ride jostle the internal wiper across a corroded or damaged strip, making the signal jump around instead of giving you a steady, honest reading.
4. The Readings Just Don’t Add Up
This is a subtler sign. The gauge works, but it’s a liar. It shows half a tank when you know it’s three-quarters, or it falls at a rate that seems all wrong. This is a clear sign the rheostat is failing progressively. It might still work for a while, but it’s on its way out and will only get less accurate.
5. You Smell Gas or See a Leak
This is the most serious symptom and needs immediate attention. The sending unit is mounted right in your gas tank. Over decades, the small fuel lines on the unit itself can rust through and leak gasoline. If you smell raw gas or see seepage around the sender’s mounting plate, your bike isn’t safe to ride. This is a critical repair for your safety—don’t ignore it.
What To Do When Your Sender Fails
If your Harley is showing any of these signs, you’ve come to the right place. Our entire business is built on solving these problems without breaking the bank.
- We Build New Units: For many models, we hand-assemble brand-new, quality replacements right here in Upstate NY, every one backed by our solid manufacturer’s warranty.
- We Can Rebuild Anything: Can’t find a unit for your classic ride? As we love to say, there are very few units ever made that we can’t repair. Our expedited rebuild service fixes rusted lines, damaged wiring, and worn parts, returning your unit to you—often better than new—with that same promise of quality.
- We’re Here to Help: Not sure about the part number? Got a question? Just give us a call at (607) 486-4001. I’m around here most days, and if I’m not, someone else who knows these units inside and out will be. We’ll help you get it figured out.
We’ve stayed focused on our original plan for 28 years: to get you a quality part at an affordable price and get you back on the road with confidence. No big dreams of corporate expansion, just a commitment to satisfying our customer’s needs, one sending unit at a time.
Don’t get stranded. Let the working people at Tri-Starr fix it for you.
