Fuel Guage Sending Unit Issue

[Phaseman]

Hello all!
Hopefully this will just be a replacement issue...

I pulled the petcock and fuel sending unit (I think that's what it's called.) off of my tank the other day. As I tried to carefully maneuver the float out of the hole in the fuel tank it popped off of the wire arm an into the tank. I was able to fish it out with some wire. Upon examination it appears that the float has worn/disintegrated beyond usefulness.

I have not been able to locate a source to replace the float and there is not enough material left on the float to determine proper placement on the rod if I were to attempt a repair.

Any suggestions for locating the part, or does anyone have a good close up of a float installed in good repair?

More pics...

[tkent02]

I bet a hunk of wood would work.

[silverhorse47]

Dirt bikes and even some lawn tractors/snowmobiles etc. all have float activated sending units. They are cheap. Look for one that matches the dimensions so it doesn't bind in the tank.
You have to find the resistance that the gauge expects to see at MT and Full by getting the specs from the factory manual for your bike. Attach the new float to the old arm carefully, so as not to wreck the resistor that makes the whole works work, saw off any excess lenght, then make sure it hits the bottom of the tank when it is not floating, and hits the top of the tank when the tank is full. Usually there is a mechanism to attach the new float to the old arm in all new kits. You might have to think a bit.
S.

[psyguy]

maybe you could fill the hole with an insert of the similar material and then re-dril the hole of the apropriate diameter?

[Phaseman]

Thanks

I was thinking of refilling the hole too, just need to find something that's fuel proof I guess.

[Old Colt]

Spray foam. The stuff for insulation purpose. It is a urethane so it's chemical properties are good.

The rod is centered in the float, might want to try and tape it there and at minimum have it level when empty just in case it is reluctant to spin afterwards.

Wood or cork are prone to sinking over time depending on how ell you can seal them.

[scotschult]

I "might" have an old sender at home, yours for the asking. I'll check this thread tonight, and if still needed, look for it.

[jacora]

Phaseman, I had similar problem and I just used a stainless steel wire to secure it front to rear very tight to the sending unit rod, It works excellent.

[doctorgonzo]

I've been MIA for a while

In the process of tearing my down for a complete winter rebuild. I have to address this issue as well. Mine is banging around in the bottom of my tank (the float). It was near the end of the season so just didn't worry abnout it (non working fuel gauge) the last month or so. I'll see what I have when I pull it out, but I bet it's in siomilar shape.

[Phaseman]

Going to attempt a repair.

Thanks for all the tips,
And thanks scotschult for the offer but It's a cash poor time year. In case things take a turn for the better what would you want for the one you have. I think the unit is fine. All I need is the float.

Otherwise, I think I'll attempt a repair. Something on the way of a cocktail straw and some spray foam.

Till I heard back from all of you guys I was over thinking it. Thinking it would have to be a certain density or something. I guess all it has to do is float and stay on the rod... The resistor mechanism will do the rest.

I'll post some pics if I get it done in any kind of an attractive way.

Thanks again!

[psyguy]

Spray foam. The stuff for insulation purpose. It is a urethane so it's chemical properties are good.

great suggestion, i think

i would definitely try this

[Big T]

Spray foam. The stuff for insulation purpose. It is a urethane so it's chemical properties are good.

Yes, but be sure to isolate the foam from the rod. That stuff sticks to everything and would prevent the rod from rotating. A piece of plastic tubing should do the trick, or a metal sleeve

[Old Colt]

the float should not spin. It should be positioned to be level in the empty position to allow it to rest close to the floor of the tank. If it were allowed to spin, it could touch the floor of the tank and hold it up a bit changing what is displayed. The sender in my bike has a groove in the float that the rod sets into locking it from rotating.

[scotschult]

Phaseman, you have a PM.

[Phaseman]

Anyone have pics?

If anyone has pics of a float in good condition I'd appreciate a post. I'm interested in seeing that groove in the float that Old Colt is talking about.