When I got my 03 Girly recently I was told by the previous owner that the fuel level sending unit was defect. Gauge showed zero and fuel light was on all the time. He included a new sending unit in our deal. I finally got the time to install it and now the gauge shows full all the time and the fuel light is out, even with only one gal of fuel in the tank. Really kinda funny.
Did I miss something? Sending unit only installs one way and the plug only connects one way, so what went wrong here?
The float inside the tube must be stuck near the top, maybe through storage. The problem usually is the other way round, the float gets stuck near the bottom as it did on mine, mind you I took mine apart and fixed it nearly 20,000 miles ago and its been OK since.
I replaced mine with a used one from a 2006 sprint.
The float for the newer generation fuel sender is black. If you take it out and open up the bottom and allow the float to drop out you will see if it is the newer one. If it is white I would not trust it.
I know you can order just the float itself from Bike Bandit but its something like $18 dollars.
I got my fuel sender on E-Bay for £7.95 plus shipping. I think after conversion it was less than $20 bucks. Keep an eye out on e-bay for one you may get lucky.
Good luck! By the way mine works just fine after replacing it.
Quote from: "Timbox2"The float inside the tube must be stuck near the top, maybe through storage. The problem usually is the other way round, the float gets stuck near the bottom as it did on mine, mind you I took mine apart and fixed it nearly 20,000 miles ago and its been OK since.
How did you fix it? I understand the gas makes the float material swell. Did you remove material from inside and outside of the float?
Quote from: "hansi"Quote from: "Timbox2"The float inside the tube must be stuck near the top, maybe through storage. The problem usually is the other way round, the float gets stuck near the bottom as it did on mine, mind you I took mine apart and fixed it nearly 20,000 miles ago and its been OK since.
How did you fix it? I understand the gas makes the float material swell. Did you remove material from inside and outside of the float?
With mine all that had happened was the float had twisted on the circuit board jamming itself, I just removed it and slotted it back on. I didnt see any signs of the float being swollen
Quote from: "Timbox2"With mine all that had happened was the float had twisted on the circuit board jamming itself, I just removed it and slotted it back on. I didnt see any signs of the float being swollen
Mine seemed to be similar. Removed it, had a look and nothing seemed out of place. Tested the board with a meter moving the float up and down and all seemed to be in order, so I reassembled it. Been working fine since. :?
Removed the sending unit today. The float was stuck against the cap of the tube. Move the cap up a little and the float moves again, lock the cap into the tabs and the float sticks again. So I drilled two holes into the cap, used zip-ties through the tab openings of the tube and through the drilled holes in the cap to give the float more room. No more sticking. Works like a charm for now. Cheap fix.
Thanks for the help, guys.