2002 K1200RS Fuel Gauge

[tpatterson12]

Fuel gauge showed empty, bike sitting in VA garage this summer, so maybe some evaporation. Filled tank to full and fuel gauge worked as it should. Started bike the next day and fuel gauge increased, but then went to zero and tank was full.

Any pointers?

- Floats
- Fuse
- Wiring

Thanks in advance!!

Terry

 

[GTRider]

A sunk float or a bad wire are the most likely suspects. Start by checking the connections at the sending unit for corrosion or disconnection. If you don’t see an issue there I’d start checking upstream, including at the gauge. If that doesn’t resolve it then pull the sending unit so it can be operated through its range with an ohmmeter on the output terminals to see if the unit is working. The sending units are NLA in the parts channel so if it is bad you’ll have to explore parters and fleabay.

My first suspicion, tho, is a bad wiring connection at the sender or upstream from there.

Best,
DeVern

 

[tpatterson12]

A sunk float or a bad wire are the most likely suspects. Start by checking the connections at the sending unit for corrosion or disconnection. If you don’t see an issue there I’d start checking upstream, including at the gauge. If that doesn’t resolve it then pull the sending unit so it can be operated through its range with an ohmmeter on the output terminals to see if the unit is working. The sending units are NLA in the parts channel so if it is bad you’ll have to explore parters and fleabay.

My first suspicion, tho, is a bad wiring connection at the sender or upstream from there.

Best,
DeVern

Thank you, DeVern - appreciate the tips.

 

[lee]

The red circle shows where the sending unit is located.


Here's a couple ebay pictures showing the float and sending unit.

 

[tpatterson12]

Thank you, DeVern - appreciate the tips.

Wire connection is good on sending unit, no visible corrosion present. Checked continuity on both brown and yellow / purple wires disconnected from fuel gauge and indicting .2 and .4 on each wire. Reconnected wires on gauge, ensure tightened and still no fuel level indicating. Looking at sending unit next.

 

[tpatterson12]

Pulled sensor, getting 4.3 ohms when sensor is inverted and 78.8 ohms when its vertical normal position. Internal sensor in tube slides freely, no dents in tube.

 

[lee]

I deleted one of my pictures. I remembered the black thing was on the filler ring and not the ring for the sending unit.

 

[tpatterson12]

Anyone taken ohm readings on your K bike fuel sensor? Looking for ohm readings before I purchase sensor. I'm getting 4.3 at tank full and 78.8 at empty. Thanks!!

 

[GTRider]

You might be at a point where the chief suspect is the gauge itself. The sending unit is free and indicating changes in output when moved through its range, and you have verified continuity between the sender and the gauge. That sort of begins to point to the gauge or the circuit powering it.

Best,
DeVern

 

[tpatterson12]

Well Murphy arrived, reassembled float and VDO fuel tank sensor, added some fuel, and what do you know the fuel gage works once again. Maybe I knocked some stuff lose when I turned wrenches and played with the electrical connectors on "JIM" today. Some K1200RS familiarization and therapy in the garage. Appreciate the tips!!

I will definitely keep an eye on it - older bike my dad, "JIM", loved and toured the US for 40k+ miles.