Graham posted a fix for the sending unit a few years ago. I tried it on my old 650 and it worked.
It’s a relatively easy fix - maybe. Drain the gas tank and remove the seat. > Disconnect the fuel sensor wire at the connector under the seat. Thread it > back towards the tank so it’s free to come out with the tank. Disconnect > the fuel line and the vacuum line at the petcock after unbolting the tank > from the frame. That way you can lift the tank enough to make disconnecting > those lines easier. Then lift and pull back the tank to free it from the > rubber grommets in the front. You may need to do a little wiggling. Now > place the tank upside down on a soft surface. I have a towel on a sponge > pad/mat on my work bench for this purpose. Undo the 4 ten mm bolts holding > the fuel sensor in place. There is a big O ring under the plate to seal it. > Gently lift the plate and the arm with the fuel sensor on the end, out of > the tank. You have to kind of turn it as you pull it out. Do it all gently > and you will see how it comes out and goes back in. > Once out you will probably see that the whole thing is probably rusted > somewhat and the arm may even be frozen in place if yours is reading 100% > full. At the end of the arm is the actual fuel sensor mechanism. It is > protected by a metal shield. You can pry that off carefully with a cutting > knife blade or similar, exposing the copper wires. The sensor works by the > contact of the wires to the pickup. You will easily see how it works. It > stops working because of corrosion and the pickup arm losing its tension > against the wires. You can carefully clean the wires and the pickup. I use > sand paper on the pick up, a small nylon brush on the wires if they aren’t > too bad. Then re-establish the tension on the arm, a little careful bending > so that the pickup is always in contact with the wires. I clean up the > whole thing with a wire brush as much as I can. There you go. Put the > shield back on, if you can, and reinstall the sensor in the tank. > Before you put the tank back on the bike, a little grease on those two > rubber grommets makes it easier. graham > -Kyle On Mon, Jun 15, 2020 at 5:07 PM gary glick <[email protected]> wrote: > The prior owner thinks the malfunction in the fuel gauge is the sending > unit. > > No new units available. > > The fuel gauge sending unit is what I am referring to. > > It might be the gauge itself, only quoting the prior owner at this point. > > Thanks > > On Mon, Jun 15, 2020 at 5:38 PM Graham Rogers <[email protected]> > wrote: > >> Are you talking about fuel gauge sending unit or ? >> >> On Mon, Jun 15, 2020 at 4:46 PM gary glick <[email protected]> wrote: >> >>> Hold out for good used ones? There are bars on Ebay for about $200 >>> delivered from Vietnam. Any body have any opinions on their quality-both >>> strength, fit and prognosis on the chrome staying chrome? >>> >>> Any possibility of repairing a failed sending unit? >>> If so then who, how or where? >>> Thanks >>> >>> -- >>> You received this message because you are subscribed to the Google >>> Groups "Nighthawk Motorcycle Lovers!" group. >>> To unsubscribe from this group and stop receiving emails from it, send >>> an email to [email protected]. >>> To view this discussion on the web visit >>> https://groups.google.com/d/msgid/nighthawk_lovers/ec518dc0-8994-40e1-8023-de8868cae0e7o%40googlegroups.com >>> <https://groups.google.com/d/msgid/nighthawk_lovers/ec518dc0-8994-40e1-8023-de8868cae0e7o%40googlegroups.com?utm_medium=email&utm_source=footer> >>> . >>> >> -- >> You received this message because you are subscribed to the Google Groups >> "Nighthawk Motorcycle Lovers!" group. >> To unsubscribe from this group and stop receiving emails from it, send an >> email to [email protected]. >> To view this discussion on the web visit >> https://groups.google.com/d/msgid/nighthawk_lovers/CAGg-qp2muhcjQOWNkbgOQvP-bd2a6G-fU2GD9t1P-xckCd6fLw%40mail.gmail.com >> <https://groups.google.com/d/msgid/nighthawk_lovers/CAGg-qp2muhcjQOWNkbgOQvP-bd2a6G-fU2GD9t1P-xckCd6fLw%40mail.gmail.com?utm_medium=email&utm_source=footer> >> . >> > -- > You received this message because you are subscribed to the Google Groups > "Nighthawk Motorcycle Lovers!" group. > To unsubscribe from this group and stop receiving emails from it, send an > email to [email protected]. > To view this discussion on the web visit > https://groups.google.com/d/msgid/nighthawk_lovers/CAOPKoDaSHovH9ni9D7BY1zoGY6omTz9XCeuW7W2TDq6LLAQsYA%40mail.gmail.com > <https://groups.google.com/d/msgid/nighthawk_lovers/CAOPKoDaSHovH9ni9D7BY1zoGY6omTz9XCeuW7W2TDq6LLAQsYA%40mail.gmail.com?utm_medium=email&utm_source=footer> > . > -- You received this message because you are subscribed to the Google Groups "Nighthawk Motorcycle Lovers!" group. To unsubscribe from this group and stop receiving emails from it, send an email to [email protected]. To view this discussion on the web visit https://groups.google.com/d/msgid/nighthawk_lovers/CAJARLXUP6Ou8M4FJ8joedn%2BdSwKuQrhxV--U04Bm%3DLK1AZcwbA%40mail.gmail.com.
