fuel gauge calibration

[krasmu]

After ordering the replacement parts to repair my missing trip odometer from Carl, I found myself in a jam when I apparently opened my gauge cluster the wrong way. I removed all the needles and the front face to get inside to the speedometer. I called Carl for help getting things back together properly and he told me he had never heard of anyone removing the needles and didn't really know the best way to get them back on in the correct position. The following is what I ended up doing. "I don't recommend this to anyone". I think it worked out but I think I could have gotten myself into deep trouble real quick.

The Speedometer needle is on a D shaft so that was a no brainer. It would go on just as it came off.
The Tach seemed to want to find a sort of "null" position when I moved it and let it find its own way. That is where I started with the needle. The temp and fuel needles were an educated guess and I didn't trust them at all. So I hooked up the wiring harness and fired up the bike. After letting it run for about 15 minutes to get it up to temp, I looked at everything. The tach seemed to be about 500 rpm high. I pulled the needle one more time and installed it at 1100 rmp. I did the same with the temp needle. I installed that at two ticks above the cold area. The fuel gauge was a different matter. I had no idea how much fuel I had in the tank. So I drained the tank, then using a gallon milk jug. (highly accurate measuring tool) and put 3 gallons in the tank. At that point I placed the needle at exactly 1/2 tank. Then I slowly drained the tank again until the needle sat on the "E". I had exactly 1 1/2 gallons left in the tank. I drained until the needle touched the "pin". I had exactly 1 full gallon left. Couldn't tell how much I have once the light came on because the bike has to be running for that.

Like I said, I don't recommend this anyone but I would like to pass on what I've learned.
1 gallon is on my PIN
2 gallons is just about 1/4
3 gallons is exactly 1/2
4 gallons is 2 ticks below the full mark
5 and 6 gallons are off the guage in the full direction.