Fuel Sender Pictures

[JHR9891]

Hi folks,

Hoping someone can help. The fuel sender does not appear to be working, resistance wise I get nothing when I test the sender with my multimeter and move the lever. The unit was badly corroded and seized so I've had to seperate it and clean it. The metal on the float arm/lever is quite badly corroded and as such I dont know if it is missing someone which should rub along the circuit board underneath it. 

Reason I say this is the board is in good condition, I have continuity between the board and both sides. If i tape my meter on different parts of the board and the red wire I do see different resistances on the meter so I am at this point thinking the issue is something to do with the lever.

As such, does anyone have any pictures of the arm (specifically between the leverand the circuit board so I can see if anything should be touching/hanging low?)

TIA folks.

[Hooli]

I might have. I'll have a look for you later if no-one else posts anything.

[JHR9891]

Thanks Hooli. Having had a play with a bit of wire if I touch both strips of the circuit board I get the resistances you'd expect, so my guess is something on the metal lever/wiper has disintergrated and just isn't contacting with those two surfaces any more. Any picsy ou have would be great. I may have to make something as I doubt you can buy individual components for it. I already had to replace the star washer on the end of the rod as that had crumbled too :(

[Hooli]

I've got a faint memory of a 'swiper arm' that does what you say. But I can't check till this evening as I'm at work.

[Hooli]

I just had a thought & looked on ebay.

Are the pics on this listing any good?

https://www.ebay.co.uk/itm/204125747365?hash=item2f86d7b8a5:g:eE0AAOSw7a9jUBgm&amdata=enc%3AAQAHAAAA4J9cXOxs14IWKBPnhS8QV0d9XyddyBb9Gw4szS%2BlRxjd49Y4Ex9BNci5AHGrPZ6edvafM5OdzuWX1918hBn9G5KNTTOrPkw17V0aMiaseUXqagZUarwZG31F%2B6QjsKHGXs6orvZhwOhZCqf197r4RWc%2Fjd8gvfTzweMh6SNv5Z9HQkJwThqwkvaC6itVEGf1Khc8CGcmQ6M1ACsO%2FLtza%2Bn9ycdiTWlhTYupCpXfe8omSWxCKbiJ8uMwN47v88HDR2eVpFL6LSRfZrJNuPFp4hgG8tdJSaD353dWkMGzpbbP%7Ctkp%3ABk9SR5Kho9zYYQ

[JHR9891]

I've seen that one, not really, I need a pic of the bit between the lever and the board (almost side on) or anyone else who has any pics of one that has been in bits.

It's not the normal sort of pic someone would take

[Hooli]

Ahh, gotcha.

[mlivkovich]

My sender didn't work, it was showing full tank when tank was almost empty...
I replaced the wire that goes from lever to "cap", just soldered new one and it works for me for 4 years now...

[urbanus]

I can take a photo of mine tomorrow when its stops blowing a bloody hooey over here - the bikes in my outbuilding and I think I'd end up blown to the Volvics if I go out tonight.

Mines a 2003 model and on the end of the lever is a very small, delicate copper wiper.  This runs over a type of resistance paint I think.  My tank was rusty as a rusty thing and it totally destroyed the wiper on the original and I think the vinegar I used to de-rust the tank took out the resistance paint.

Anyway, if you don't get it sorted by over the weekend I should be able to get you a photo if you still need it.

[JHR9891]

Hi all,

Figured I'd drop a quick update for you all in case anyone bumps into this issue. So my original wiper had, as first thought, totally disintegrated. As Suzuki doesn't do individual spares for the sender unit I had a look on ebay and had a look at the quad/generic fuel sender units which looked similar. I bought one for about £10 quid and low and behold it was identical. All I did was transfer the float/rod onto the arm - add a couple of washers and the star washer and away we went.

All works fine and was fixed for pretty much nothing. I've attached some pics for reference. I hope this is useful for someone in the future.

EDIT: Trying to post last pic but says "Path can't be empty" so will try from another machine

[Eric GSX1400K3]

Well done, great result.  Not only water in fuel, or old stale fuel, but sulphur in fuel attacks the electrical connectors and printed cb's.

Re the pictures, it will do that if the file size is too big.

[JHR9891]

And finally a pic of the new wiper, apologies, was from Amazon - https://www.amazon.co.uk/B08X6V941C (POEFT Universal Scooter Dirt Bike Fuel Tank Sending Unit Petrol Level Gauge Sensor) I used some M2/M2.5 washers and the star washer which came with the new unit to get a nice tight fit.

[JHR9891]

Well done, great result.  Not only water in fuel, or old stale fuel, but sulphur in fuel attacks the electrical connectors and printed cb's.

Re the pictures, it will do that if the file size is too big.

Yeah I'll be honest, the inside of the tank, the pump and sender are the worst I have ever seen. It has been sat for a very, very, very long time. Still the pump looked awful but cleaned up ok and ran after I changed the rubber seals for the filter/pressure regulator. Time will tell if it stays that way!