TOPIC:

Does anyone have a working fuel gauge sender unit, or know where I can get a new one. I have tested the gauge in my instrument cluster and it is working fine,so have tested the sender unit in the tank which is faulty.
Cheers.

Have you pulled it apart sometimes with senders you can bend and manipulate them so that the moving component runs on a new path and they work fine again.

aus_z1300 wrote: Have you pulled it apart sometimes with senders you can bend and manipulate them so that the moving component runs on a new path and they work fine again.

Agreed. You should be able to pull it apart and clean the copper contact that rides on the stainless wire and get it working again. It's nothing more than a variable resistor. Worst that usually happens to them is moisture in the fuel corrodes the copper contact and the sender unit goes open circuit. Sometimes the pivot pin gets slightly bent from shock and the copper contact is not riding on the stainless wire.

The one I have now on the bike had the fine wire from the windings broken just where it's soldered on to the contact that goes thru the unit to the outside, a bit of a bodgie fix I did was to solder a bit of thicker copper wire onto the contact and make a bit of a "pig tail" on the other end by wrapping it around a pin, slide that fine wire into it and solder it in place, the fine wire from the winding was too small to solder, so I did my usual backyard fix, ok the resistance will be out but heck it works, may not be exactly accurate but I never get below a half tank anyway, cheers Pete

So these are repairable then? I have spare that was in rough shape, I'll give this a try and post some pictures. It would be nice to know if these are fixable or not.

kza13 wrote: The one I have now on the bike had the fine wire from the windings broken just where it's soldered on to the contact that goes thru the unit to the outside, a bit of a bodgie fix I did was to solder a bit of thicker copper wire onto the contact and make a bit of a "pig tail" on the other end by wrapping it around a pin, slide that fine wire into it and solder it in place, the fine wire from the winding was too small to solder, so I did my usual backyard fix, ok the resistance will be out but heck it works, may not be exactly accurate but I never get below a half tank anyway, cheers Pete

the resistance in the wire is linear so if you unwrapped one coil then resoldered you would have removed as an example 1 wrap of 30 wraps is 1/30th of a change which is peanuts.