Valkyrie Fuel Gauge-V3 Installation Instructions
Valkyrie fuel gauge-V3 installation instructions:
The fuel gauge set includes the following components:
· The analog micro-controlled fuel gauge.
· Fuel sensor unit with micro-controller (the black box)
· Extension cable with the red, black and yellow wires.
· White T-piece 10x10x6 (or 8x8x6)
· Fuel Hose 6mm 27cm
· Fuel Hose 10mm (or 8mm) 4.5 cm
· Hose clamps 3x no.17 (or 3x no.14)
· Hose clamps 2x no.9
· Tie Wraps 5x
· Velcro pad 47mm round
· White plastic fuel sensor box support
· Screwdriver 2mm
· Documentation
Important:
Don’t remove the closure tape on the hose connection before installation.
Do not yet apply any pressure on the sensor connection.
The sensor unit contains glycerin inside.
You should not spill any of the glycerin.
Do not tilt the box when the hose connection is open.
Connecting the T-piece to the fuel hose:
For fixing the T-piece on the fuel hose, the fuel tank must be removed.
First, the saddle needs to be removed.
Switch the fuel valve to close.
Then remove the screw in the middle of the fuel valve.
Place it back later in the same position.
Then remove the larger bold holding the rear of the tank to the frame.
Loosen the smaller bolt holding the tank at the neck (front) end, but do not remove it.
Pull the rear of the tank up and place something like a wooden block under the lower side to raise it a couple of inches. There should be enough slack in the hoses to allow this, but be gentle.
Then loosen the three hose clamps holding the three hoses from the fuel tank, the fuel hose,
the vacuum line and the overflow hose. Gently pull off these hoses from the tank.
There may be some fuel spill, so you may want to have a rag under the fuel valve area.
The tank can then be removed.
The next job is to connect the T-piece into the line of the fuel hose.
Cut 3cm (1.2 inches) off the existing fuel hose that feeds the fuel from the fuel valve to the carburettors.
It is important to cut off sufficient hose here. If you do not then the extra length of hoses provided in the kit can cause the fuel hose to kink, cutting fuel supply.
Important: Use a sharp knife. Don’t let any rubber fibers get into the fuel system.
Connect the fuel hose with the white T-piece so 27cm (10.6 inch) of the sensor hose is directed
to the right side of the bike.
The other side of the T-piece towards the tank is mounted with the 4.5 cm (1.8 inch) long 10mm or 8mm fuel hose supplied.
Important: Put a bit of oil on the T-piece so it will go easy into the fuel hose.
Attach the hoses to both sides of the white T piece using the new hose clamps provided.
Attach the other two hoses (breather and overflow) to tank.
Place the sensor hose behind the ignition key.
It will fit exactly through the opening behind the key.
Be sure to place it horizontal.
After routing through the ignition key opening the sensor hose must descend towards the Electronics box.
Important: Fuel can evaporate if it is heated, creating gas in the line.
This gas needs to flow smoothly upwards into the tank to disperse.
The sensor fuel line needs to be descending all the way to the sensor unit so the gas can escape easily. If not placed correctly, the indication on the gauge may be wrong.
Installing the gauge and wiring:
The function of the wiring:
Red = 12 volt
Black = 0 volt (frame)
Yellow = pressure signal from the sensor
Place the fuel gauge on the handlebar or between tacho and speedo.
If you want to attach the gauge to the handlebar then use a handlebar clamp.
The clamp is not included in the set.
Run the cables so that they meet under the plastic cover in front of the fuel tank, and then connect one side to the other. Connect color to color.
Route the cable towards the middle of the bike.
The three connectors on the mid section of the cable should be located near the seatlock.
Use the five Tie Wraps to secure the cable.
From there the last section of the cable must be placed below the right side cover
of the bike.
The power supply red and black wires are connected to the accessory connector,
located near to the fuse box.
If there is no free connection then use the attached splitter cables.
If you choose to connect them differently, always use a 5 amp fuse.
Placing the new fuel sensor box:
Place the electronics unit near the seat lock.
The led and potentiometer should be to the left side of the bike.
Use the round Velcro pad to mount it to the plastic cover where the seat lock is located.
Put the Electronics unit far enough to the back to not disturb the function of the seat lock.
The bottom of the unit should rest against the chrome metal clutch bleeding nipple.
The fuel tank can now be re-fitted by bolting it back into place.
Re connect the chrome outer part of the fuel valve to the inner by screwing it on.
Make sure it is replaced in the same position as before (so that the outer ‘off’, ‘res’, and ‘on’ markings really do equate to the same positions of the actual fuel valve.
It is possible to connect 90 degrees out, potentially leading to fuel cut off).
Initial Set Up: bleeding the system:
Now you need to bleed any trapped air out of the new line to the fuel sensor unit.
After fitting the tank, remove the electronics unit.
Remove the closure tape on the fuel line connection of the electronics unit.
Attach a clamp no.9 to the sensor fuel line but do not tighten it.
Warning !!!
Only place the sensor fuel line over the sensor connection when the engine is running
and the fuel valve is open so the fuel can run freely.
If you place the fuel line over the connection while the engine is not running,
there will be a increase in pressure inside the fuel line.
The pressure may increase above the absolute maximum pressure and damage the sensor.
Important: Put a bit of oil on the fuel line connector to facilitate the connection.
Place an absorbent cloth or a bottle under the sensor fuel line.
Set the fuel valve to normal and start the bike.
Now fuel will flow out of the sensor fuel line.
Make sure to capture the spilled fuel.
Let the fuel flow until all air is gone from the sensor fuel line.
Now press the sensor fuel line over the fuel connection on the electronics box,
while the fuel is flowing.
Tighten the clamp no.9
Important: Make sure all the air is removed from the sensor hose.
If there is any air left in the sensor hose the indication on the gauge will be wrong.
Initial Set Up: connecting the fuel sensor wiring
Connect the wires color to color.
Then place the Electronics unit back near the seat lock.
Be sure the fuel line to the sensor is not kinked and does not leak.
Place the white plastic support by removing the rubber cap on the chrome metal rod.
Place the support piece over it like in the picture.
Put the rubber cap back in place.
Initial Set Up: calibrating the new fuel sensor
The adjustment should be performed with full fuel tank and engine running!
The electronics unit contains an led and a control screw.
The control screw is located behind the small black plug under the led.
Remove this plug and keep it safe to place it back later on.
To calibrate the system for initial set up, the procedure is to gently turn the control screw,
using the screwdriver provided, so that the led changes colour from bright green to red.
The correct point is just between the red and the green.
On this correct point the led will be blinking green. (Occasional blinking red is fine.)
Now replace the small black plug.
After this calibration it is necessary to restart the bike.
Your new Valkyrie fuel gauge is now ready for use!
Using the Fuel Gauge system:
After switching on the power of the bike the led will alternate between
red and green for a few seconds as a system test.
The gauge will show below zero.
This means there’s no fuel pressure because the fuel valve is closed.
At this time the led will flash green once a second.
When starting the bike, the gauge will show full for a few seconds.
This is a gauge test.
After that it will show the fuel height inside the tank.
The led should be green or blinking between red and green.
If the fuel is low the led will not light.
The amount of fuel shown on the gauge at this moment is only an estimation.
It needs three minutes of averaging out to get a correct value.
Until this time the pointer may move a bit up or down.
After three minutes the pointer can only move so slowly that it’s not visible.
It’s recommended to set the fuel valve on time to the reserve position.
If you do not set it to reserve on time there may get some air into the fuel line.
This may cause the gauge to show a to low value after a while.
If you trust the fuel gauge system then just leave the fuel valve on reserve.
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