Faulty fuel gauge?

[Travis398]

A search pulled up a few posts on the subject

You can read how easy it is here http://www.fjowners.com/index.php?topic=1893.msg14999#msg14999

And the picture you was looking for here http://www.fjowners.com/index.php?topic=2026.msg15992#msg15992

[markmartin]

A search pulled up a few posts on the subject

And the picture you was looking for here http://www.fjowners.com/index.php?topic=2026.msg15992#msg15992

Thanks for the leg work Travis.  I'm having the same problem with mine. 

I'm assuming that the little hole in the middle of the winding is the one that was drilled to add the Dimethicone.

Mark

[FJTillDeath]

Just to make sure but do you need to plug the hole up after the oil has been put in? and what would you use to close it up with?

[Bozo]

Travis398, you're a champion thats exactly what I needed. FJt somebody wrote to plug the hole with silicon rubber (obviously after you've cleaned around the hole with some metho) while the unit is laying side ways. If you have a better way let me know, thanks to all that participated in the forum (mainly to the one that started it).

P.S whatever metho is left over - enjoy. Don't drink and ride.

[markmartin]

A search pulled up a few posts on the subject
And the picture you was looking for here http://www.fjowners.com/index.php?topic=2026.msg15992#msg15992

Thanks for the leg work Travis.  I'm having the same problem with mine. 

And thanks andyb for posting the picture in the first place. 

[Travis398]

Yes, thank Andy.

[Bozo]

Just to make sure but do you need to plug the hole up after the oil has been put in? and what would you use to close it up with?

FJt, just did my fuel gauge mod, I used a match stick (cut down) to plug the hole and I added the rubber sealant around that. At first I only used the sealant but that appeared to go down the hole which would've stop the movement once dry.

I'll go for a ride on the weekend and see how it works.

[FJTillDeath]

Okay well my fuel gauge really does wonders. in my days of absence, when i opened the throttle properly the fuel gauge would spin violently in circles then the next day it stayed stiff no problem at all. needless to say I tried the mod anyway and from what i can see today the guage appears to be working perfectly, I fillied it up with some reallt fast drying silicone seal stuff my uncle borrowed me that turns to rock hard plastic in less than 5 minutes. I will keep riding and keep everyone posted but for now it seems fine

[Bozo]

Ok, this is getting spooky. I did the fuel gauge Mod and it still bounces. The worst is that yesterday the bike went sick and looked like it was running out of fuel. I found that the 12volts going to the fuel sensor (red/green) goes to three items - fuel relay, Ignitor, and the fuel warning light.
I believe that if the voltage on the red/green wire drops down through a bad connection (or other) the fuel pump will deactivate thinking the tank is on reserve which eventually cuts the fuel pump unless the Reserve switch is ON. Also if the voltage on the red/green drops and the fuel is FULL the gauge is 'over sensitive' causing the gauge to react quicker (causing quick needle fluctuations)
Therefore it looks like my problem is the red/green wiring to relay and ignitor (the voltage comes from switch and the kill switch). I might add that I hot wired all other wires to gauge and sensor apart from the red/green. The sensor has been changed out and I have three fuel gauges showing same symptoms.
Keep you posted once I find out more.

[FJTillDeath]

I got a similar problem to Bozo I repaired the fuel gauge and thought it was working but now I see something weird. whenever the bike is full of petrol the needle is fine but when it gets to halfway until the empty line it will bounce like mad. then when it gets under the empty line until finaly empty tank its perfectly fine again. WTF ??

[Bozo]

The other telltale that the voltage is low on the red/green wire is that the red light on the fuel reserve warning is dull, like I stated previously because the voltage goes low, the fuel pump cuts out thinking that the fuel is low therefore cutting the fuel pump but it doesn't light the red fuel light because that uses the earth through the fuel sensor separately. If the reserve switch is activated the it should prevent the fuel from cutting out.

I suspect my wiring at the junction points is breaking down (somewhere in the wiring loom, my bike was bought from a guy who left it in the rain for two years), unfortunately the voltage appears ok till the wires get resistance gradually dropping the voltage, aaaaaaaaaaahhhhhhhhhhhhhhhhhhhhh I hate intermittent wiring. As soon as I find the culprit I'll let you know.

[Bozo]

Found it, the Green/red (not red/green as previously stated) wire on the igniter just fell out the minute I touched it. Looks like most of the wires are corroded so I'll have to replace the connector. Unfortunately I pulled the bike apart to find the fault.