FUEL SENDER ASSEMBLY

[dorbar10]

Hello, my FZS 600 2002 had a broken fuel sender unit.
I bought a new unit, but when i connect it to the tank the gauge still shows "EMPTY" all the time, even when the tank is fully filled. I removed it from the tank while it was still connected by wire and moved the float unit up and down to see if there is any reaction, and there was.
Outside the tank it works perfectly, but inside it shows empty. My guess is that im doing something worng in the assembly process, anyone got an idea how to fix it? on which direction does the floating unit should point?


thanx.

[Fazerider]

Sounds rather as if the float is sinking. Is that new too, or did you move it across from the old assembly?

[red98]

Sounds rather as if the float is sinking. Is that new too, or did you move it across from the old assembly?

iam with fazerider 

[dorbar10]

You are probaly right, its sinking, i bought a used unit, i guess the float is damaged, any ideas how to fix it?

[Fazerider]

Tricky. If you can find a hole it might be possible to weld it closed with a soldering iron. Otherwise if it was the sensor on the old one that failed and you still have it, the float on that might be OK.
To answer the other part of your question, I think the arm faces backwards when mounted in the tank. In fact, I guess if it's possible to fit it the wrong way it would be more likely to read high.

[dorbar10]

Thanx

[Fazerider]

Was there any fuel visible in the float when you took it out? (Just thinking it's unlikely to have managed to drain itself dry if there is a leak.)
You can test for holes by pushing it under in a bowl full of hot water, it'll blow bubbles.

[Jamieg285]

I know next to nothing about this yet, but just throwing in a suggestion.  Could it be anything to do with the electrical earth? i.e. when you put the sender in its earthing out?