TOPIC:

Thanks guys. When the fuel level gets down a bit I will remove the sender unit and have a play, see what I can do to fix it.

speaking of the sender unit, mine has a plastic float, wonder if the overseas guys ones are swelling and dissolving because of the alcohol in their fuel like their carby floats ?? maybe another item that can be made of brass ???

I was looking at a ZX1100 fuel sender unit on ebay, which is only a couple of numbers different in part numbers. The unit is slightly taller in height, to accomodate a different tank style , but the sender unit and float look similar to the Z1300. Thought it may be possible to swap the two units over maybe.
Just a thought.

Ok, so I have taken the sender unit out and dismantled it. Wow, what a load of crap I found trapped in there. Mainly corrosion. From what I could see there was a big blob of rust that was wrapped around the small thin wire where it attaches to the plastic insulation block where the wire exits out from the unit. This blob of rust had broken the fine wire,( just like yours Pete ).
I carefully cleaned all the rust / scale out and very carefully cleaned the blob of rust from around the small fine wire.

Next I stripped a section of old original wiring I have, and extracted one strand of wire. I wasn't to sure if I was able to do it but I managed to very carefully solder a new section of wire in. Next I cleaned up the contact on the slider that rubs up and down on the resistance coils and rebent it in to make a better contact, as it was not making contact all the way up.
When all this was done I tested it on the bike with success, the gauge now works again.

I refitted the casing around the sender unit and retested the unit, still working fine. Put it back in the tank and sat the tank back on the bike, reconnected the wiring and tested again, low and behold it still works.

Thanks again to all for your advice.

For the record, it's just 304 stainless wire. if you mic the wire and replace with the same diameter you'll be fine.

I'm going to be cleaning a rusty fuel sender over the next few days. I did talk with a local shop they suggested that an old VW sender might match up. (attached below). Thank you everyone a head of time for the info on this thread. I'll updated on my success... our failure haha. 


www.amazon.com/Empi-98-2021-0-Fuel-Tank-...a-572038757428&psc=1

This site also has newly fabricated senders FYI 
www.z1300.de/