Fuel Sender Replaced

[Seaking]

Finally got around to changing my fuel sender unit. Though the fuel gauge hasn't indicated proper fuel quantity for a couple of years, last month it started to do the 8 blinks and some other weirdness. But this wasn't constant, it would kinda work or not work.. mostly not work..

 

Changing the sender is simple easy to do, takes longer removing the tank and re-installing it than it takes to pull out the old and install the new sender. Drainning as much fuel as possible out of the tank makes it less of a mess. Once the 4 bolts are removed and the wire bundled unclamped, all it takes a tilt and a turn to worm the works out of the hole.. Re-installing is simple as following the same tilt and turn in reverse. A new gasket to ensure no leaks.

 

Examining the old and comparing it with the new sender showed that the wire swing arm of the float is loose at the pivot point and allowed to lean away and break contact from where the points touch on the unit to indicate swing arm position. This would explain why the fuel gauge readings were so helter skelter.. Not sure if tightening the swing arm in some way would bring it back to life as new again.. Regardless, the new sender wasn't expensive and it was easy to replace.

 

With the sender out of the way, I was also able to retrieve the lost gas cap bolt that fell out earlier this year. I also observed that the fuel in the tank had some black stringy particles floating around in it. Large enough that the fuel valve strainer would catch it but none the less, the tank will come off this winter and get a proper steam cleaning to get it all out.

 

Test riding the bike and running a couple tanks of gas through it shows that the new sender works. No more flashing, it showed 0 fuel on the gauge and fuel light illuminated on my way to the nearest gas station to fill up and once topped up, the gauge read full.. Once past 55 miles on the ODO the gauge dropped one notch, then at 75 miles another notch and so on.. until 175 miles the fuel light came on and at 185 miles the engine coughed to go onto reserve. Not bad. Everything works as it is supposed to.. Though I'm wondering if it's reading a little high.. The last time it worked properly, I would see the first notch around 40 miles or so on the ODO..

 

After so many years just relying on the ODO for fuel management, it's nice to have a working fuel gauge again.

 

Attached is photo of old and new fuel sender..

[WillyB]

I've been having this same problem. Thanks for the post pics.

[YamahaLarry]

Mine varies a little as to what mileage it drops first notch after a fill up. If I am lazy or in a rush and fill with it on the kickstand, usually around 35 to 40 miles it will drop first notch and then at around 165 or so I will get the low fuel warning light. If I sit on the bike and fill it standing straight up, the first notch is at around 55 miles or so and the low fuel light will come on around 180 or so miles.

 

Most of my driving is back and forth to work. Several traffic lights with a 10 mile or so no light cruise at 45 to 60 mph.

[Venturing Sole]

My fuel gauge blinked and fuel light and trip meter didn't work for darn near 20-30,000 miles. Finally replaced the fuel sender unit even though diagnostics were inconclusive. As you said, the procedure is simple and the unit was not too expensive. Instantly worked right when I replaced mine about a year ago.

[sho_greg]

Should the contacts touch?? I have about a 1/32 or so of movement... I got a new fuel sender unit but it did not include the float and float contacts..

[videoarizona]

I get about 40-45 miles before I lose the first bar. But I've never seen the warning light...I go into reserve without warning. I just replaced the bulb...we shall see if that was the problem.