Fuel Gauge . ( FJ1200 88 -89 model. )

[Jeff0308]

I have been looking at the posts previously posted regarding fuel gauge senders. I was going to ask question however, the post said last post was over 120 days old and to start a new one, so here goes again. I saw the posts and pics that Flips and Chockers  put up but what I want to find out has anyone ever taken the sender out of 88-89 model or are they all the same? My tank I think has a litre or just over left in it and NO light and I havent switched the reserve on yet :scratch_one-s_head:The gauge still reads but when I took the take off the tank the other day it had bugger all in it? ( The gauge did read empty but no light as yet) I do know the tank has been off before .  I am tempted to just ride till it runs out but that presents 2 more problems. A long walk and dirty carbs. I wanted to adjust the float, since I have to remove everything again I might as well do it all at the same time.  The sender on this model? is it at the back of the tank underneath as there is a what looks to be circuit with wires coming off it, still connected I presume.  If I disturb the gasket whats the recommended for either another gasket or a sealant? The other thing I am hearing alot about it tank treatment against rust (POR 15 ). Is this stuff used alot or is it a waste of time?   Jeff

[Arnie]

Jeff,
Are you sure the light works?  Could just be a blown bulb.

Why not carry a 4 or 5 litre fuel can (with fuel) until it splutters to a stop.  Then you'll know what the gauge reads and if the light and switch still function.
A fuel filter will prevent dirty carbs caused by sediment in the tank.

I haven't used POR15, but its more a treatment to seal and coat rust rather than a preventative.  Supposed to work well.

Arnie

[flips]

Hi Jeff.

The fuel senders appear to all have the same part no...

http://www.boats.net/parts/detail/yamaha/Y-36Y-85752-03-00.html

I suspect Arnie may be onto something with the lamp (if its blown don't replace it with an led lamp)

The sender is towards the front of the tank on the right if your sitting on the bike.

I have had the sender out a few times and have just applied a little hi temp gasket silicone to the rubber seal on the sender before re assembly and have had no leaking issue's.(the seal on mine appeared to be in good condition...if it looks crappy I would replace it..you don't want fuel leaking from there!  )

POR is good stuff.I have used it on a few different tanks but its really only for leaking tanks.Pat posted some good info on the topic...

http://www.fjowners.com/index.php?topic=8450.msg78560#new

If you have the vacuum operated petcock /gravity fed fuel system,you might wanna check this thread out too  ...

http://www.fjowners.com/index.php?topic=3265.0

Cheers 

Jeff P

[Jeff0308]

Thanks Arnie / Jeff Never thought to carry fuel  around. Sure as hell beats walking. As far as the light goes. When the bike is in gear and the stand is down press the start button and the FUEL and OIL lights come on so the globe works ok. I know there is a fuel filter on there as I saw it last week. As for the POR 15. I have thought about it but havent really looked in to it. I have used the KREME product about 20 years ago on an old XJ900 but havent compared them. I know FJ tanks are hard to find in good nick. Thought of it as a prevention but yet to decide on it. Fix the headlight issue first I think. If there is moisture in the tank a bit of metho might be the go.  I think when the tanks off i might try empty it out and see what comes out. Hopefully nothing.

[Woodsman]

Had mine apart recently shook it around with a chain inside and rinsed it till it came out clean.Had a pinhole soldered. Didn't go down the sealer route as i hate the thought of it breaking up. The fj tank has a lot of eneven surfaces and valleys that are hard enough to get clean and dry. Sender unit went back on and didn't leak, just bolted it back on and bench tested for a night.
Sean.

[fj11.5]

im using a tank i sealed with por15  3 years ago and its holding perfect,, ill be sealing the 88 soon, as its clogged the fuel filter with rust, bad enough to stop it running

[Harvy]

Jeff, you mention the fuel light does work when you press the starter button, so the globe is good. I believe this is correct, even when the sender unit is unplugged. So..... are you sure the sender unit is plugged into the loom and/or the sender unit does not have a broken wire?
AS others have said, its easy to check. Take a multimeter, set it on resistance and probe the connector coming from the tank. Slosh the tank around (just rock the bike from side to side will do the trick) so that the unit is changing resistance......you will easily see if its working or if there is a broken wire.

HTH
Harvy

[Jeff0308]

I took the bike out today to see about the suspension ans well as an excuse for a ride as well as the FUEL light issue. Thanks arnie for the thought on taking extra fuel. Took the mower fuel with me. The gauge reads no prob and as i suspected was low. It got me 54km on empty til it ran out at the bottom of my street. The reserve I dont think is working. When I got home I took the tank off and removed the sender. Next to nothing for fuel in it not even a quarter of a  cup full. I am suspect that the tank has had a hole in it as it has a big solder mark a quarter of the way up in the middle of the hump? The sender appears to read fine as I connected it back up and turned on the ignition for a couple of seconds. It went to full and empty and even in between when I moved the float. Didnt appear to be in bad condition either and also untouched so I can only assume its never been bent. Stiil ...NO LIGHT??? Did find that  the sender gasket had a split in it between the bolt hole and the circular cutout so I ordered a new one. Here thursday. Still NO LIGHT???  ARGGGGG I hate it when I cant find a solution to a simple puzzle. I did however find out that some knob has disconnected the side stand and over ridden it. Bollox to that. If its there I want it to work. Again got to source one. That wont be to hard. Can still get them new. 2 week wait ex japan. $112 australian. Sender can still get to. $134. new. I had a talk to the yAMAHA dealer about the light and he seems to think that the light was only an option an the 89 model not 88 as it wasnt released in america. However the old owner told me today that it worked. I also asked him about him knowing the sidestand switch was unplugged. Said he never knew. Now Im questioning his credibility.  I know its only a light but if its there it should work. also the reserve issue? Its got me buggered.

[oldktmdude]

   Jeff, the fuel light has nothing to do with the fuel gauge. The light has it's own sender unit which happens to be attached to the gauge sender, but operates independently. I had to replace my sender unit because my low fuel light also wasn't working. I ended up buying a NOS unit from ebay for around $25 which by a lucky coincidence just happened to come up for sale just as mine shit itself.  Sorry I didn't see your post earlier, as this may have helped you sooner.   Regards, Pete.

[Jeff0308]

Hi Pete. Thanks for the response. I read your post just now. As I understand it the GAUGE  and the FUEL light are incorporated in the sender unit in the tank  but work independantly  to each other? So basically if the light doesnt work the gauge does? Which is the case on mine. Strange part is I suspected that but wasnt sure. The only other thing I have yet to address is the RESERVE SWITCH. Mine didnt appear to make any difference whether it was in the NORMAL or RESERVE position. That part has me stuffed.  :scratch_one-s_head:Its the first time I have ever put myself in the position of running out of fuel which I did on purpose to see what works and what doesnt. ( HAD THE MOWER FUEL ON BOARD just in csae) The fairing has to come off anyway so I might have a look at the switch to see if its corroded any. On a plus i did find a 3mm crack in the sender gasket so its not a lost cause.  :good2:While its apart I will have a look at the fuel lines and put a new filter on  as well. Only want to do it once.  

[oldktmdude]

Hi Pete. Thanks for the response. I read your post just now. As I understand it the GAUGE  and the FUEL light are incorporated in the sender unit in the tank  but work independantly  to each other? So basically if the light doesnt work the gauge does? Which is the case on mine. Strange part is I suspected that but wasnt sure. The only other thing I have yet to address is the RESERVE SWITCH. Mine didnt appear to make any difference whether it was in the NORMAL or RESERVE position. That part has me stuffed.  :scratch_one-s_head:Its the first time I have ever put myself in the position of running out of fuel which I did on purpose to see what works and what doesnt. ( HAD THE MOWER FUEL ON BOARD just in csae) The fairing has to come off anyway so I might have a look at the switch to see if its corroded any. On a plus i did find a 3mm crack in the sender gasket so its not a lost cause.  :good2:While its apart I will have a look at the fuel lines and put a new filter on  as well. Only want to do it once.  

The gauge and low fuel are definitely incorporated in the sender unit but on independent sensors. Sorry I can't help with your reserve switch problem as my '85 doesn't have one and have had nil experience with one. There are several other members on here that have had issues with it, so an answer to your problem will be forth coming I'm sure.  Regards, Pete.