Yamaha Rhino Fuel Gauge

Disclaimer: Consult your Yamaha dealer concerning warranty issues before performing this modification.

Supplies Needed:
1 Stewart Warner 240 ohm Fuel Tank Sender part # 392 B-F
2 Stewart Warner 240 ohm Fuel Gauge part # 82303
3 5-each #10 stainless steel sheet metal screws 1 inch long
4 5-each #10 nylon or teflon washers these can be found at Ace hardware, Lowes, Home Depot etc.
5 5-each 16 gauge electrical ring terminals with #10 hole
6 2-each #16 gauge electrical ring terminals with 5/16" hole
7 20 foot #16 gauge electrical wire
8 1 bag of black TY-Raps
9 Electrical tape

2. Drill 1 1/2" hole in the tank with a hole saw on the right hand side closest to the engine. The hole should be in the center section of the tank to the right of the vent in the top of the tank. Before cutting all the way through the tank, dust away the plastic to keep it from falling into the tank and go slow with the drill so the plastic cut out will stay on the drill. Remove any pieces that may have fallen into the tank with a air hose suction or any other suitable means.

3. Follow instructions in the fuel tank sender box for setting sender to correct tank depth.

4. Put gasket on tank and install sender in the tank. Drill 5 each 9/64" pilot holes through the sender mounting holes into the tank. Insert nylon washers on #10 stainless screws and attach sender to the tank. On one of the # 10 sender mounting screws attach a #10 ring terminal to a piece of #16wire 8" long and ground to the sender. Make sure the ring terminal is on the sender side of the nylon washer for proper grounding. Attach a 5/16" ring terminal to the other end of the wire and ground to the seat mounting bracket closest to the engine.

5. Attach # 10 ring terminal to a piece of # 16 wire and hook up to the center terminal on the fuel sender this piece should be about 15 foot long.

6. Remove the skid plate bolts in the center skid plate to be able to route the wire to the front of the Rhino for gauge installation. You will only need to remove 7 of the skid plate bolts the skid plate does not need to be removed all the way only enough to route the wire. Run wire to the front of the Rhino toward the headlight switch following the existing wire harness. Place TY-Raps on wire to keep away from driveshaft and prevent from rubbing on anything. TY-Rap wire to square tubing all the way across to the head light switch.

7. Drill one 2 1/16" hole in the dash for the gauge 3" to the right and 2 1/2" up from the center of the headlight switch. Note: DRILL ONLY ONE HOLE!

8. Mount gauge. Attach sender wire from the tank to the S terminal on the gauge with ring terminal.

9. Attach an 8" piece of # 16 wire to the G terminal on the gauge with a ring terminal attach the other end of the wire to a 5/16" ring terminal and ground to a bolt on the square tubing.

10. Attach a piece of # 16 wire about 8" long to the I terminal on the gauge with a ring terminal this will be the power wire for the system. Find the red wire on the plug of the headlight switch. Strip the insulation back on the red wire and solder the other end of the wire attached to the I terminal on the gauge to this wire. Attach the wire from the light in the gauge to this same red wire and solder as well. Tape solder connection with Electrical tape. You can use a scotch ock for this installation if you do not want to solder however I prefer soldering for a better connection.

11. Turn on key and make sure gauge reads empty. Adjust sender if necessary. See instructions in fuel tank sender box for adjusting instructions.

12. Fill Tank turn on key and make sure gauge reads full. Adjust sender if necessary. See instructions in tank sender box for adjusting instructions.

Disclaimer: Not responsible for any damage to your machine or accuracy of this information. Do not try this on your machine.