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Fuel gauge sending unit repair with pics

This explains why mine works when it's full but then drops away to empty after about 35 miles & stays there then.... :)
 
bump back to the front page for people with this question recently, and i nominate it for a sticky?
 
Glad this got resurrected, but I have a question. One of my bullet connectors let go finally. Although the unit never did read well in the 2 years I've owned my beast, after I redid both bullet connectors with spade connectors, using dielectric grease and then insulating them well, and then refilling my tank with exactly 3 gallons of gas, the gauge read the 1st time I started the bike. So far, it hasn't worked again for a week now, staying below the "E" line. Suggestions?
 
My GS110ED gauge was not working either

My GS110ED gauge was not working either

I pulled the sensor (I was Por-15 sealing the tank anyway) and checked the resistance; it basically came down to bad connections which I cleaned and resoldered and now all works fine. :rolleyes:

Posplayr
 
PAULYBOY said:
Glad this got resurrected, but I have a question. One of my bullet connectors let go finally. Although the unit never did read well in the 2 years I've owned my beast, after I redid both bullet connectors with spade connectors, using dielectric grease and then insulating them well, and then refilling my tank with exactly 3 gallons of gas, the gauge read the 1st time I started the bike. So far, it hasn't worked again for a week now, staying below the "E" line. Suggestions?
Click to expand...

Normally, that means the wires are backwards, I believe. But you say it worked briefly? When did it stop?
 
i dunno about you pauly, but my sending unit was working fine. i've traced the issue to my headlight bucket and i'm confused. i was under the impression that the grey wire in the deal ( if i'm look at the diagram right ) is a ground.. but i'm reading 1.2 volts on it when i test it back to ground, and nothing at all when i test it back to the + .. there is another 12 volt hotline (orange) in the plug, so i'm confused :P
 
I have a good one, mine failed, I checked the connections, looked good, but replaced anyway, still doesn't work. I go to fill the tank and notice a large black plastic rectangle floating freely around in the gas tank.... well there's your problem right there!
 
Awesome

Awesome

I am pretty new here,and just wanted say that your post is Really the kind of thing I came to this site in search of.Anyone with a couple bucks can buy a replacement,but instead of a link to a dealer or fische site.You showed us all how to repair what we already have!!!! Although I dont need this particular info right now,I know where to find it when I do!!
Thanks a bunch,and happy riding to you!
 
Dogma said:
Normally, that means the wires are backwards, I believe. But you say it worked briefly? When did it stop?
Click to expand...
On most of our bikes, the white/black wire is ground. Anyway, the unit has never worked 100%, but since only 1 wire broke, and it wasn't the ground wire, I couldn;t have possibly connected them wrong, because when I repaured the broken one I used spade connectors, and the other is still the now clean,pretty,and greased up bullet connector. And, yes, I made sure to tighten up the bullet connector that was still on there. I think I just might need to do this adjustment. It's just a basic rheostat type deal, I'm just too lazy to drain and remove my tank AGAIN for the umpteenth time this year. But, then again, when its off, I'll have another excuse to paint more, different, even stranger things on my bike!!!
 
Wow, this thread has legs!

I'm glad people have gotten some use out of my tinkering.
 
Try this first

Try this first

My recent GS650 purchase had many problems including the fuel gauge. The previous owner told me the guy he purchsed it from said it hadnt worked for a couple of years and had been checked over etc etc. After reading this article I decided to pull the sender unit and see if it was beyond repair, adjusted the tension but there was still no reading then Duh!! I realised that the spade connector on the unit that is steel was badly corroded. A quick rub some petroleum jelly and a new connector and all was hunky dorry. I now know the potentiometer will be ok for a long time now. Thank you Jethro.
 
Awesome thread!!! We need more of this kinda thing from senior members! Hats off Jethro! :clap:
 
What does the hose that comes off the cover to the sender do ? Its open to the air anyway under the cover it goes on because the cover doesnt go over the whole sender ?
 
in case the sender unit gasket leaks, it diverts the leak away from the motor.
 
jwhelan65 said:
Awesome thread!!! We need more of this kinda thing from senior members! Hats off Jethro! :clap:
Click to expand...

Hey! There ya go! My 15 minutes of fame has lasted years with this thread!

Glad to see people are still getting some good use out of this!
 
Nice infom Mr. Jethro.

I rebuilt my GS1150 gas sending unit and gas gauge last week. That
was a pain-in-the-ass after taking it off 5-6x. Make sure the sending
unit is good with an analog Ohm meter whereas you can see the sweep
from 0-100 Ohms as you move the float up and down. And that it is stable throughout the entire sweep without any glitches. Just remove and bend the tap. Once this is good, the rest will be point to the meter as suspect.

My situation was unique, as it reacted very different. It would always
stay at 3/4 full with nothing in it. The short test goes to full, and needle
does not go to zero when open.

So, the guage was and is the suspect after passing the gauge test. I found the 56 Ohm resistor completely separated from the PCB, as it tested fine out of the circuit. I've never seen a soldered resistor comepletely fall-off a PCB. When it is hooked-up, the resistance will
be pulled down to 35 Ohms, so the resistor must be isolated to test, or have one end desoldered and measure across resistor.

Mine is working great now as it should. I also recommend 10-25-40-60-
80 Ohm 1/4W resistors resistors to aid in the troubleshooting procedure.
It is a very simple economic technique as resistors are only a few cents each.

I can't ride a bike without a gas gauge !!

:D
 
Thanks for the explanation on the hose to the sender cover, makes sense now.
 
just did this on my 81 1100e and now the needle moves :D don't know how accurate it will be, but its cool. i always keep track of my miles per tank.
 
Hey Jethro,

did the 2 wires from the sending unit have the same end connectors or were they different/opposite so that it would only be connected to the harness 1 way?

Paul
 
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